BRPI0812509B1 - reforming apparatus and method - Google Patents

Description

Report of the Invention Patent for "REFORMING APPARATUS AND METHOD".

Field of the Invention The present invention relates to apparatus and methods for reforming gaseous hydrocarbons and more particularly to apparatus and methods of low coke, low metal dust formation and high efficiency for reforming gaseous hydrocarbons. Steam reforming is a catalytic reaction in which a mixture of steam and gaseous hydrocarbons is exposed to a catalyst at high temperatures to produce a mixture of carbon oxides and hydrogen, commonly known as syngas. Syngas can be further converted into a wide range of bulk and specialty chemicals including hydrogen, methanol, ammonia, transport fuels and lubricants.

The chemical reactions involved in steam reforming have been well known for many years. In fact, steam reforming has been used by industry since the 1930s and natural gas steam reforming has been the dominant method of hydrocarbon production since the 1960s, when high pressure operation was introduced.

Two potential problems that arise with reforming reactions include the formation of metal dust and coke, which can result in process inefficiencies and equipment failure. Metal dust formation occurs when the combination of temperature, pressure and composition within a carbonaceous gaseous environment leads to corrosive degradation of the powdered alloys. Metal dust formation conditions can be difficult to avoid in reforming systems, so metal dust formation is a constant threat. Coke occurs when gaseous hydrocarbons crack to produce a solid carbonaceous material that can obstruct or damage the flow path, which can lead to heat transfer inefficiencies and talk and equipment failure.

Industrial steam reformers are conventionally tubular in construction, employing several large metal tubes packaged with the reforming catalyst. The hydrocarbon / steam feed mixture flows through the tubes, contacting the catalysts and undergoing conversion to syngas. Since reforming reactions are endo-thermal, heat must be supplied to maintain the required reforming temperatures (usually above 800 ° C). In conventional tubular overhaul systems, this is accomplished by placing pipes in a combustion furnace, usually ignited by natural gas, where heat is transmitted to the pipes by a combination of convective and radiant heat transfer.

Thus, the successful operation of a tubular reformer is based on maintaining a somewhat delicate balance between endothermic reforming reactions within the tubes and heat transfer to the tubes from furnace combustion. The heat flow through the pipe walls must be high enough to maintain the temperatures required for reforming reactions, but not so high as to increase excessively high metal wall temperatures (accompanied by reduced strength) or to give rise to coke. hydrocarbon in hot spots inside the pipes. Therefore, the operation of tubular reformers must be subjected to strict control.

While large-scale tubular reformers have been very successful both technically and economically, smaller-scale tubular reformers are less successful. Among other things, the manufacturing, installation, maintenance and operation costs of tubular reformers on a smaller scale are not attractive.

Smaller users of downstream syngas products such as hydrogen, ammonia and ethanol therefore did not find it interesting to set up on-site production facilities for these products. Rather, they are generally based on truck distribution of product cylinders from large-scale products. This solution is becoming less attractive as the price of transport fuels increases. In addition, many of these natural gas users prefer to have on-site production facilities not only to avoid transportation costs but also to improve the reliability of their supply. Additionally, much of the world's natural gas supply is based on small fields in remote regions not served by pipelines for the natural gas market. The energy content of this so-called "stranded gas" can be more easily transported to the market if the gas is first converted to liquids such as methanol and long stream hydrocarbons, which can be produced from syngas.

Therefore, there is a need to produce syngas on a smaller scale than was economical and practically possible with conventional tubular systems, and this need should increase. There are considerable challenges, however: a smaller scale system must be reasonably proportional to the large scale installation at initial cost, and operating costs must also be commensurate with the production scale. Low operating costs require high energy efficiency, minimizing natural gas costs, simplicity of operation, and minimizing or preventing the need for attention for full-time plant operators.

While the amount of heat required by reforming reactions is fixed by thermodynamics, the overall efficiency of energy use in the factory depends on the efficiency with which heat is recovered from hot syngas and hot fuel combustion streams to preheat the feeds. for reforming temperatures and raise the required steam. High efficiency feed effluent heat exchangers and the use of combustion heated preformers can assist in this regard. Importantly, while large-scale reform systems may claim energy efficiency credits for the excess steam energy content exported to other on-site processes, small-scale reform systems should not have an export destination available to them. excessive steam and thus its production does not improve efficiency.

Both initial and simplified operational capital costs can be improved by minimizing the use of active control, using instead passive control techniques where possible. For example, proper division of a single current to pass to multiple components connected in parallel can be achieved by arranging appropriate relative pressure drops across these components without the use of control valves. As a further example, the temperature of a stream leaving a heat exchanger may be kept within limits by the arrangement for the heat exchanger to operate with a small temperature narrow.

An additional consideration in smaller scale systems is that the user may not operate continuously at or near full plant capacity, in contrast to large scale plants. Therefore, modulation of performance across a wide range must be achievable and subject to automation, such as quick start and shutdown procedures. The smaller scale reformer should also minimize maintenance requirements.

Thus, there is a need for a smaller-scale reform process and apparatus that achieves the goal of being cost-competitive and operational with large-scale systems as a result of the simplicity of control, monitoring and maintenance along with High energy efficiency.

Brief Summary In some embodiments, a gaseous hydrocarbon vapor reforming process and / or apparatus may be designed to limit the occurrence of metal dust formation conditions in localized parts of the apparatus or process. In some embodiments, localized parts of the apparatus or process to which the occurrence of metal dusting conditions are limited may include a fuel preheater in which a fuel / air mixture is partially combusted to heat a fuel stream from from below the metal dusting temperature to above the metal dusting temperature.

In some embodiments, localized parts of the apparatus or process to which the occurrence of metal dust formation conditions are limited may include an air preheater in which a fuel / air mixture is combated to heat an air stream from below the metal dusting temperature to above the metal dusting temperature. In some embodiments, localized portions of the apparatus or process to which the occurrence of metal dusting conditions are limited may include a pipe portion adjacent to a cooling heat exchanger where a portion of the syngas stream is formed during The reforming process is cooled from above the metal dusting temperature to below the metal dusting temperature. In some embodiments, localized parts of the apparatus or process to which the occurrence of metal dusting conditions is limited may include a process piping part where the cooled syngas is mixed with a second part of the syngas which has not yet been filled. cold.

Accordingly, in some embodiments, the gaseous hydrocarbon vapor reforming process may include: a) preheating one or more air streams to form one or more preheated air streams; b) combining at least one air stream with a part of at least one fuel stream to form a fuel / air mixture having a temperature below the metal dusting conditions; c) partial combustion of the fuel in a portion of the fuel / air mixture to form a heated fuel stream having a temperature above the metal dusting conditions for use in one or more stages of the reformer; d) combustion of a fuel / air mixture portion in the presence of at least one of the preheated air streams to form a heated air stream having a temperature above the metal dust forming conditions for use in the reform for use in a or more stages of the reformer; e) heating one or more streams of water to form steam; f) mixing the vapor with one or more gaseous hydrocarbon streams to form a gaseous hydrocarbon vapor stream; g) heating and partially reforming the gaseous hydrocarbon vapor stream at one or more of the pre-reforming stages to form a reformer stream, where through all one or more pre-reforming stages the gaseous hydrocarbon vapor stream has a combination of temperature and composition that prevents the formation of metal dust and coke conditions; h) reforming the reforming stream into one or more stages of reformer to form a syngas stream and a flue gas stream, where through all one or more stages of reforming the reformer stream has a combination of temperature and composition which avoids the conditions of metal dust and coke formation; (i) heat recovery from the flue gas stream to provide heat to the preform stages in step g) and provide preheat to the water stream; and j) recovering heat from the syngas stream to preheat the air stream from step a) and to provide heat to steam in step e).

In some embodiments, the process or apparatus comprises a process or apparatus for reforming gaseous hydrocarbon vapor to produce syngas where the gaseous hydrocarbon feed rate is from 1 to 10,000 standard cubic meters per hour ("SCMH"). In some embodiments, the process or apparatus is configured to minimize, prevent or localize the occurrence of metal dust and / or coke formation conditions throughout the steam reforming process. Preferably, the process or apparatus is configured to avoid the conditions of metal dust formation in heat exchangers, reforming stages and pre-reforming stages of the process or apparatus. Preferably, the process or apparatus is configured to avoid coking conditions in the fuel supply streams, pre-reform and reform stages and / or syngas streams.

In some embodiments, the process or apparatus comprises a process or apparatus for reforming gaseous hydrocarbon vapor to produce syngas, wherein the process has a hydrocarbon conversion of more than 50% and less than 95%. In some embodiments, the process or apparatus comprises a process or apparatus for reforming gaseous hydrocarbon vapor to produce syngas, where the process has an energy efficiency of more than 50%. In some embodiments, the process or apparatus comprises a process or apparatus for reforming gaseous hydrocarbon vapor, where all the steam required for the process is generated and used within the process, that is, there is no vapor export from or import of steam into the process.

In some embodiments, a gaseous hydrocarbon vapor reforming process or apparatus comprises a passive flow control system whereby the appropriate amount of fuel and air is distributed to various points in the process, such as preheaters, pre-reform stages. and / or reforming stages by balancing pressure drop within heat exchangers, pre-reformer stages and / or reformer stages.

In general, vapor reforming of gaseous hydrocarbon streams is considered to involve the following reactions: (1) and (2) Equation (1) is reduced to: (3) where the gaseous hydrocarbon is methane.

Brief Description of the Drawings Figure 1a illustrates a scheme of one embodiment of a reforming system. Fig. 1b illustrates a schematic of an alternative embodiment for a portion of the reforming system according to Fig. 1a, Fig. 5 and Fig. 7.

Figures 2a to c illustrate plate schemes that can be used to form a syngas heat recovery heat exchanger embodiment 110 as identified in figure 1a.

Figures 3a and b illustrate plate diagrams that can be used to form a heat exchanger embodiment 164 as identified in figure 1a, figure 5 and figure 7.

Figures 4a to d illustrate plate schemes that can be used to form a heat exchanger embodiment 166 as identified in figure 1a, figure 5 and figure 7. Figure 5 illustrates a scheme of an alternative embodiment of a reforming system.

Figures 6a to c illustrate plate schemes which may be used to form a syngas 510 heat recovery heat exchanger embodiment as identified in figure 5. Figure 7 illustrates a scheme of an alternative embodiment of a reforming system. Fig. 8 illustrates a scheme for one embodiment of reformer module 150 as identified in FIG. 1a, FIG. 5 and FIG. 7 including a reformer and pre-reformer;

Figures 9a to e illustrate plate schemes which may be used to form a pre-reformer embodiment.

Figures 10a and b illustrate plate diagrams that can be used to form a cell in a preformer.

Figures 11a through f illustrate plate schemes that can be used to form a reformer embodiment.

Figures 12a-d illustrate plate schemes that can be used to form a cell in a reformer.

Figures 13a and b illustrate a bottom view of a stack of plates forming a preform (figure 13a) and reformer (figure 13b). Figure 14 illustrates desired temperature profile trends for reformer airflow and reformer current in one embodiment. Figure 15 illustrates one embodiment of a flow resistance network for air and fuel currents in a reforming system.

Figures 16a-d illustrate plate schemes that can be used to form a reformer embodiment. Figure 17 illustrates a simulated syngas temperature distribution for a reformer cross-flow heat exchanger without regard to wall conduction. Figure 18 illustrates a simulated syngas temperature distribution for a reformer cross-flow heat exchanger taking into account wall conduction. Figure 19 illustrates a graph of composite hot and cold temperature enthalpy curves for process streams in one embodiment of a reformer system. Figure 20 shows a front perspective view of a partial configuration for one embodiment of a reformer system 100. Figure 21 illustrates a rear perspective view of a partial configuration for a embodiment of a reformer system 100 shown in Figure 20.

Definitions Metal powder formation conditions: the combination of temperature and composition within a gaseous carbonaceous environment that leads to corrosive degradation of structural materials and powder alloys. In general, metal dust formation occurs at intermediate temperatures between 400 ° C and 800 ° C and where the gas phase carbon activity ("ac") is greater than 1. Since metal dust formation is a As a result of a combination of temperature and composition in a given stream, these variables can be manipulated to prevent or reduce the occurrence of metal dusting conditions. Accordingly, for some compositions, the upper limit for metal dust formation may be less than 800 ° C such as 700 ° C or 750 ° C and the lower limit may be greater than 400 ° C such as 420 ° C or 450 ° C. Thus, it should be understood that 400 ° C to 800 ° C should be a general rule, but there are other exceptions and metal powder formation conditions may involve the combination of composition and temperature. Accordingly, when such an application mentions that "metal dusting conditions are avoided or reduced" and the like, it is intended that the combination of variables that may lead to metal dusting conditions be avoided or reduced by manipulation. temperature, composition or both.

While it is not desired to be limited to any theory, the formation of metal dust is considered for the most part the result of the following reactions: (4); and (5) Accordingly, metal dusting conditions may be avoided or reduced by manipulating the temperature and / or composition of a gas stream to avoid such reaction situations and to avoid conditions in which ac> 1. Alternatively, the process and / or apparatus may be designed to limit the occurrence of metal dust formation conditions at localized points of the process and / or apparatus to minimize repair requirements, minimize the difficulty and cost of repair and minimize the use requirements of costly alloys or coated materials that are resistant to metal dust formation.

Metal Dust Resistant Materials: Metal dust resistant materials are materials that resist corrosive degradation when exposed to metal dust formation conditions. Any materials that are resistant to metal dust formation and are suitable for the relevant process conditions such as temperature and pressure may be used. In some embodiments, metal dust resistant materials may be Alloy 617, Alloy 617 coated with an aluminide coating or Alloy 800H coated with an aluminide coating. The aluminum coating can be formed by depositing aluminum on the surface of the material, diffusing it into the alloy at high temperatures and oxidizing it.

Catalysts: In general, when the term catalyst is used herein in connection with reformation and combustion of beds or chambers, it is intended to include any suitable catalyst, such as any precious or non-precious metal catalyst or mixtures and combinations thereof, which may be be a structured or unstructured catalyst and may be a supported or unsupported catalyst, suitable unstructured catalysts may include porous particulate catalysts that may be sized optimally to achieve the desired reforming reaction or combustion while maintaining the desired pressure drop within of the relevant current. Suitable structured catalysts may be coated on a wire mesh or foil support or on a ceramic matrix. In some embodiments, the catalyst may comprise a metal catalyst comprising a metal selected from: gold, silver, platinum, palladium, ruthenium, rhodium, osmium, iridium, or combinations of one or more thereof. In some embodiments, the catalyst may be a platinum / palladium catalyst on an alumina washcoat support coated on a fecralloy (ferro-chrome aluminum) sheet metal matrix.

Alternatively, when using the term catalyst to refer to a water-gas change reaction catalyst, it is intended to include any suitable catalyst such as a non-precious or precious metal catalyst or mixtures and combinations thereof which may be be a structured or unstructured catalyst and may be a supported or unsupported catalyst. Suitable unstructured catalysts may include porous particulate catalysts which may be their size optimized to achieve the desired water-to-gas change reaction while maintaining the desired pressure drop within the relevant current. Suitable structured catalysts may be coated on a wire mesh or foil support or on a ceramic matrix.

Description of the Figures In some embodiments, the process or apparatus comprises a process or apparatus for reforming gaseous hydrocarbon vapor to produce syngas where the gaseous hydrocarbon feed rate is 1 to 10,000 cubic meters stopped per hour ("SCMH"). , such as 2 to 500 SCMH, such as 1 to 10, 10 to 100, 100 to 1000, 1000 to 10,000, 10 to 4000, 15 to 3000, 20 to 2000, 30 to 1000, 40 to 500, 50 to 250, or 60 to 100 SCMH.

In some embodiments, a syngas gas reforming steam reforming process or apparatus may have a hydrocarbon conversion of 50% or greater such as from 50% to 95%, such as 55% to 90%. 60% to 85%, 65% to 80%, or 70% to 75%.

In some embodiments, a syngas gas hydrocarbon vapor reforming process or apparatus may have an energy efficiency of from 50% to 90%, such as 55% to 85%, 60% to 80% or 65% to 75% when calculated according to the following equation: where LHVs = the amount of heat released per mole (or per kg) from the combustion of the syngas product, excluding latent heat in water;

Ms = the amount of heat released per mole (or per kg) from fuel combustion, excluding latent heat in water; LHVf = the amount of heat released per mole (or per kg) from fuel combustion, excluding latent heat in water;

Mf = the molar flow rate (or mass) of fuel; LHBmg = the amount of heat released per mole (or per kg) from natural gas combustion, excluding latent heat in water; and Mmg = molar flow rate (or mass) of natural gas.

In some embodiments, the process or apparatus comprises a gaseous hydrocarbon vapor reforming process or apparatus having the efficiencies described above and where all the steam required for the process is generated and used within the process, ie there is no steam export from or import into the process.

In some embodiments, the process or apparatus is configured to minimize, prevent or localize the occurrence of metal dust formation and / or coke conditions. Preferably, the process or apparatus is configured to avoid metal dusting conditions in the heat exchangers, pre-reform stages and / or process or apparatus reform stages. Preferably, the process or apparatus is configured to avoid coke conditions in gaseous hydrocarbon feed streams, fuel feed streams, pre-reform and reform stages, and / or syngas streams. In some embodiments, the process and / or apparatus may be designed to limit the occurrence of metal dust formation conditions at localized points or components of the process and / or apparatus, such as at localized points of the process or apparatus that may be designed. or constructed from protected, dust-resistant materials and / or configured for easy and / or economical repair and / or replacement.

In some embodiments, the gaseous hydrocarbon vapor reforming process or apparatus comprises a passive flow control system whereby the appropriate amount of fuel and air is distributed to various points in the process, such as the preheat and combustion stages. reforming system by balancing pressure drop within heat exchangers, pre-reform stages and / or reform stages.

In some embodiments, the gaseous hydrocarbon vapor reforming process comprises: partial combustion of the fuel in a first fuel-air mixing stream to heat the first fuel-air mixing stream for use during vapor stream reforming hydrocarbon gas; combustion of a second fuel-air mixture stream to heat an air stream for use during reforming the gaseous hydrocarbon vapor stream; and reforming the gaseous hydrocarbon vapor to form a syngas stream and a flue gas stream. Partial combustion may comprise catalytic oxidation of at least a portion of the fuel in the first fuel and air mixture stream to provide a heated fuel stream. Partial combustion may utilize all or substantially all of the air in the first fuel and air mixture stream. After partial combustion, the heated fuel stream may be supplied to one or more reforming stages for further combustion to heat or reheat one or more air streams. Combustion of the second fuel and air mixture stream may comprise catalytic oxidation of all or substantially all of the fuel in the second fuel and air mixture stream to provide a heated air stream. The heated air stream may be supplied to one or more reforming stages to provide heat to the gaseous hydrocarbon vapor stream being reformed. The resulting cooled air stream may then be heated or reheated, for example, by combustion of a portion of the heated fuel stream in the presence of the cooled air stream.

In some embodiments, the reform includes pre-reforming the gaseous hydrocarbon vapor stream to form a reformer stream prior to reforming the reformer stream. In some embodiments, reforming includes reducing the formation of metal dust and / or coke during reforming by heating and pre-reforming the gaseous hydrocarbon vapor stream at multiple pre-reforming stages to form a reforming stream prior to reforming. reform of the reforming current. In some embodiments, the pre-reform includes partial reforming of a portion of the gaseous hydrocarbon vapor stream. In some embodiments, partial reforming includes multiple pre-reforming stages, each stage including a) heating of the gaseous hydrocarbon vapor stream followed by b) partial catalytic reforming of the gaseous hydrocarbon vapor stream. Heating may include heat recovery from a flue gas stream of the reforming process. The number of pre-retirement stages can be from 1 to 10 as well as from 2 to 7 or from 3 to 5 pre-retirement stages. In some embodiments, pre-retirement is performed at multiple stages to help prevent or reduce coke conditions during pre-retirement and retirement. In some embodiments, coke conditions are avoided or reduced during pre-reformation by changing the composition and / or temperature of the gaseous hydrocarbon vapor stream. In some embodiments, pre-reformation is conducted in a printed circuit reactor ("P-CR"). The reforming current may be reformed in one or more stages of catalytic reform. In some embodiments, the reform is conducted in a PCR. In some embodiments, the reform comprises from 1 to 40 stages of reform, such as from 2 to 35 stages, 3 to 30 stages, 5 to 25 stages, 8 to 20 stages, or 10 to 15 stages of catalytic reforming. In some embodiments, reforming the gaseous hydrocarbon vapor stream includes at least three stages of: i) heating the reforming stream by recovering heat from a heated air stream in a heat exchanger to form a heated reforming stream and a stream. air cooled; (ii) renovation of at least part of the heated reforming current; and iii) combustion of a portion of a partially blown air-fuel mixture stream in the presence of the cooled air stream to reheat the cooled air stream.

In some embodiments, reformer stream heating includes heat recovery in a heat exchanger of a heated air stream, such as the heated air stream created by combustion of the second fuel and air mixture stream, or the stream. of heated air created by the combustion of a portion of the partially mixed fuel and air mixture stream in the presence of a cooled air stream to reheat the cooled air stream. In some embodiments, the heat exchanger may comprise a simultaneous flow, cross flow or counter flow heat exchanger. Preferably, the heat exchanger comprises a cross flow heat exchanger. In some embodiments, the heat exchanger comprises a printed circuit heat exchanger. Preferably the pressure drop across the heat exchanger to the heated air stream is less than 10 kPa (0.1 bar), such as less than 9 kPa (0.09 bar), less than 7 kPa (0.07 bar). ), less than 6 kPa (0.06 bar) or less than 5 kPa (0.05 bar). In some embodiments, the pressure drop across the heat exchanger to the reformer current is less than 50 kPa (0.5 bar), such as, for example, less than 40 kPa (0.4 bar), less than 30 kPa. kPa (0.30 bar), less than 20 kPa (0.2 bar) or less than 10 kPa (0.1 bar). Reforming at least a portion of the heated reformer stream may include catalytic reforming of a portion of the heated reformer stream to produce syngas. Reforming can be conducted through a series of catalytic reforming stages to maximize hydrocarbon conversion while reducing or avoiding coke conditions in the reformer current in the reformer. Preferably, the conversion of the gaseous hydrocarbon occurs according to equation (1). Additionally, additional hydrocarbon production may occur through the water to gas changeover reaction as follows: (6). that can approach balance during retirement and pre-retirement.

In some embodiments, combustion of a part of the partially blown air-fuel mixture stream in the presence of the cooled air stream to reheat the cooled air stream includes catalytic combustion of a part of the partially blown air-fuel mixture stream. in the presence of the cooled air stream. In some embodiments, the part of the partially blown air-fuel mixture stream is supplied separately to the catalytic combustion chambers of a portion of or all reformer stages. In some embodiments, the part of the partially blown air-fuel mixture stream supplied to the reformer stages is the same amount of the partially-blown air-fuel mixture stream for each supplied reformer stage.

In other embodiments, the portion of the partially blended air-fuel mixture stream supplied to the reformer stages varies depending on the stage supplied. In some embodiments, the amount of partially combusted air and fuel mixture supplied to one or more of the combustion stages of the second and subsequent stages of the reformer may be less than that supplied to one or more of the preceding stages. For example, in some embodiments, the amount of partially mixed air and fuel mixture stream supplied may be successively reduced for each reform stage and in some embodiments, one or more subsequent stages of reform may have no part of the mixing stream. fuel and partially combusted air supplied to them. Preferably, the amount of partially combusted air and fuel mixture supplied to the reformer stages is reduced for each successive stage and may be zero for one or more stages. The part of the partially blended air-fuel mixture stream supplied to each reform stage can be controlled using active or passive controls. Preferably, the part of the partially blended air-fuel mixture stream supplied to each reform stage is controlled using passive flow control. Such passive flow control may be accomplished by balancing pressure drops in fuel streams, air streams, fuel and air mixture streams and / or their component streams throughout the reformer and heat exchange components of the process. reform.

After the last reform stage has been completed, two streams leave the reformer from where heat can be recovered. The first stream is the syngas stream, which is the reformed gaseous hydrocarbon vapor stream. The second stream is the gas stream which is the air stream leaving the last heat exchanger from the last reformer stage. Each of these currents is at relatively high temperatures.

In some embodiments, the process or apparatus achieves the efficiency described herein in part by recovering the heat from the flue gas and / or the synga streams leaving the reformer stages. In some embodiments, heat is recovered from the syngas stream that enters one or more reaction supply streams, such as one or more of: a gaseous hydrocarbon stream, one or more fuel streams, one or more streams. and one or more streams of water in one or more heat exchangers. In some embodiments, heat is recovered in one or more heat exchangers from the flue gas stream to heat the gaseous hydrocarbon vapor stream in one or more of the preform stages. In some embodiments, heat is recovered from the flue gas stream by both the gaseous hydrocarbon vapor stream and one or more water streams. In some embodiments where heat is recovered from the flue gas stream by both the gaseous hydrocarbon vapor stream and one or more water streams, the flue gas stream is heated prior to heat exchange with the gas stream. water by combustion of a part of at least one fuel stream in the presence of the flue gas stream. In some embodiments, the water stream recovers heat from both the flue gas stream and the syngas stream. In some embodiments, heat is recovered from at least a portion of the syngas stream by cooling at least a portion of the syngas stream in a cooled heat exchanger.

In some embodiments, the gaseous hydrocarbon vapor reforming process comprises: a) preheating one or more air streams to form one or more preheated air streams; b) combining at least one air stream with a part of at least one fuel stream to form a fuel and air mixture having a temperature below the metal dusting conditions; c) partial combustion of the fuel in a portion of the fuel and air mixture to form a heated fuel stream having a temperature above the metal dusting conditions for use in one or more stages of the reformer; d) combustion of a portion of the fuel and air mixture in the presence of at least one of the preheated air streams to form a heated air stream having a temperature above the metal dust formation conditions for use in one or more stages. the reformer; e) heating one or more streams of water to form steam; f) mixing the vapor with one or more hydrocarbon gas streams to form a gaseous hydrocarbon vapor stream; g) heating and partially reforming the gaseous hydrocarbon vapor stream at one or more pre-reforming stages to form a reformer stream, where at all or one of the preforming stages the gaseous hydrocarbon vapor stream has a combination of temperature and composition that prevents the formation of metal dust and coke conditions; h) reforming the reformer stream into one or more stages of reformer to form a syngas stream and a flue gas stream, where at all one or more stages of reforming the reformer stream has a combination of temperature and composition. which prevents the formation of metal dust and coke conditions; (i) recovering heat from the flue gas stream to provide heat to the preform stages in step g) and to provide preheat of the water stream; and j) recovering heat from the syngas stream to preheat the air stream of step a) and to provide heat to form the stream in step e).

In some embodiments, the air stream is preheated by heat recovery from the syngas stream in a heat exchanger. In this way at least a portion of the heat remaining in the syngas stream can be recovered, thereby improving process efficiency. The air stream may be any suitable air stream, such as a process air stream or a blown air stream, and may be conditioned or unconditioned, such as filtered or unfiltered, purified or unpurified, or humidified or unmixed. moistened.

Preferably, the air stream may be a forced air stream provided from a blower or other blown air source. Generally, it is preferable for air to be supplied at sufficient pressure for process requirements, rather than at excessive pressure that can cause process inefficiency due to increased blower energy requirements. Accordingly, the process and apparatus are desirably configured to minimize the required process air pressure, which can be accomplished by avoiding large pressure drops through process components such as heat exchangers, valves and pre-stages. - reform and reform.

In some embodiments the combination of at least one air stream with a part of at least one fuel stream to form a fuel and air mixture having a temperature below the metal dusting conditions includes the joining of an air stream. and a fuel stream. In some embodiments, the at least one air stream is a part of the air stream discussed above before or after the air stream is preheated. In some embodiments, the at least one air stream is a part of the air stream discussed above prior to preheating. Thus, there may be a single air stream supplied to the system or process that may be split into two or more air streams before or after preheating. One or more of the air streams may be preheated in the same or different heat exchangers by heat recovery from the syngas stream.

In some embodiments, the fuel stream may be preheated by heat recovery from the syngas stream, such as in a heat exchanger. In some embodiments, a portion of the fuel stream that is combined with at least one air stream is preheated in the same heat exchanger in which one or more of the above described air streams are preheated. The fuel stream may be a part of any combustion fuel supply stream for steam reforming processes, such as off-gas or end-gas streams of a pressure change adsorption (PSA) process, at from a methanol production process or from an ammonia production process, or it may be a mixture of an off-gas or final gas with a gaseous hydrocarbon stream or streams such as natural gas streams, methane streams , propane streams, gas hydrocarbon mixtures, refinery exhaust gas or other exhaust gas or end gases and mixtures or combinations thereof. The conditions during preheating are preferably maintained to reduce or prevent the formation of metal dust and coke conditions in the fuel stream and heat exchanger. The at least one air stream and part of the fuel stream may be joined in any suitable manner, such as by joining the chains to form a single chain using a Ύ "or" T "connector or by adding a chain. In some embodiments, at least one air stream and part of the fuel stream may be joined in the heat exchanger by combining the heat exchange streams of the two or by feeding the streams to the same exchanger outlet. Preferably, the resulting fuel and air mixture is fuel rich and capable of incomplete combustion only due to the limited amount of air in the stream.

In some embodiments, after the fuel-air mixture is formed, it may be split into two or more streams using any suitable splitting mechanism, such as a Ύ "or ..ρ. Pe | 0 connection at least one part. The fuel and air split can be partially combusted, as catalytically combusted, to form a heated fuel stream, which may have a temperature above the metal dusting conditions. Preferably, combustion is partial as a result of limited air in mixture In some embodiments, the heated fuel stream may contain substantially no combustible air and may include fuel and combustion by-products In some embodiments, during combustion of the fuel and air mixture, the stream experiences dust formation. and / or coke conditions In such cases, the chain components associated with combustion, including the combustion chamber, are preferably constructed from metal dust resistant materials such as metal dust resistant alloys or alloys that have been coated with metal dust resistant coatings and / or are configured for repair, removal and replacement easy. Preferably, the temperature and composition of the heated fuel stream after combustion is suitable for use in the reformer stages without any further modification and is such that the heated fuel stream will not undergo the conditions of metal dust and dust formation. coke within the stages of the reformer.

A second part of the fuel and air mixture may be combusted, such as catalytically combusted in the presence of a preheated air stream to form a heated air stream for the reformer stages. In some embodiments, the heated air stream may have a temperature above the metal dusting conditions. Preferably, the fuel in the fuel and air mixture is completely or substantially completely combusted to provide additional heat to the preheated air stream.

In some embodiments, heating one or more streams of water to form steam includes heat recovery from a flue gas stream and / or a syngas stream. In some embodiments, heat recovery from a syngas stream includes heat recovery from a syngas stream at two different points in the gaseous hydrocarbon vapor reform process, such as shortly after the syngas stream has ceased. the stages of reformer and just shortly before the syngas stream left the process.

In some embodiments, one or more water streams recover heat from the gas stream in a heat exchanger after the flue gas stream has left the reform and pre-reform stages, just as before the gas stream. of combustion leave the reform process. In some embodiments, the flue gas stream may be combined with a portion of the fuel stream and / or the gaseous hydrocarbon stream and then preheated by combustion, such as catalytic combustion, the fuel stream portion and / or the stream. hydrocarbon gas in the presence of the flue gas stream before entering the heat exchanger, but after the flue gas stream has left the reform and pre-reform stages. In other embodiments, such as those in which reinforcement is conducted as a high temperature reforming process, this combustion step may not be included or utilized.

In some embodiments, the water stream recovers heat from a portion of the syngas stream shortly after the syngas stream leaves the reformer stages, the recovery occurring in a cooled heat exchanger in which the incoming syngas stream raises steam. by heat exchange with a stream of water in a heat exchanger that is submerged in water. In such embodiments, as the heat exchanger is submerged in water, metal dusting conditions are avoided as a result of the relatively constant temperature of the metal due to boiling water, together with insufficient pressure to vent the point. boiling water to metal dusting temperatures. Although the heat exchanger does not suffer from the conditions of metal dust formation, the syngas stream shortly before entering the cooled heat exchanger may suffer from such conditions. Accordingly, that portion of the syngas tubing within at least five pipe diameters from the inlet to the heat exchanger is preferably constructed from materials resistant to metal dust formation, such as alloys resistant to metal dust formation or alloys that have been coated with metal-resistant coatings and / or that are configured for easy repair and / or removal and replacement. In some embodiments, most of the steam that arises and is used in the gaseous hydrocarbon vapor reforming process arises in the cooled heat exchanger. In some embodiments, the syngas stream is divided to form a first syngas stream and a second syngas stream and heat is recovered in the cooled heat exchanger from one of the first and second syngas streams.

In some embodiments, the water stream recovers heat from the syngas stream shortly before the syngas stream leaves the process of reforming the gaseous hydrocarbon stream. In some embodiments, such heat recovery occurs in the same heat exchanger as heat recovery for air and fuel streams as discussed above. In other embodiments, a separate heat exchanger is used for heat recovery within the water stream from the syngas stream shortly before the syngas stream leaves the gaseous hydrocarbon stream reforming process.

In some embodiments, after one or more streams of water have been heated to produce steam, the steam is mixed with one or more gaseous hydrocarbon streams to form a gaseous hydrocarbon vapor stream. Mixing can be accomplished by joining a vapor stream with a gaseous hydrocarbon stream to form a single stream using any suitable socks such as using a Ύ "or" T "connector or by adding one stream within the other. In some embodiments, the gaseous hydrocarbon stream has been preheated, as preheated by heat recovery from the syngas stream, such as in the same heat exchanger or a different heat exchanger as the heat recovery for streams. Gaseous hydrocarbon stream may be any gas reforming hydrocarbon stream, such as natural gas, methane, propane, gas hydrocarbon mixtures, refinery gases or other combustion gases and mixtures. In some embodiments, the ratio of vapor to gaseous hydrocarbon in the gaseous hydrocarbon vapor stream may be be indicated by a vapor to carbon ratio. In some embodiments, the ratio of vapor to carbon in the reformer stream may be from 1: 1 to 12: 1, such as from 2: 1 to 10: 1 from 3: 1 to 8: 1 or from 4: 1 to 6. :1.

In some embodiments, the gaseous hydrocarbon vapor stream is preformed into one or more preform stages. In some embodiments, the one or more pre-reforming stages include heating and partially reforming the gaseous hydrocarbon vapor stream to form a reforming stream. In such embodiments, the partial reforming may comprise one or more stages of heating the gaseous hydrocarbon vapor stream by heat recovery of the flue gas stream followed by the partial catalytic reforming of the gaseous hydrocarbon vapor stream. In some embodiments, at least 2 pre-retirement stages are performed, such as 2 to 10, 3 to 10, 4 to 8, or 5 to 7 pre-retirement stages, such as 2 or more, 3 or 4 or more or 5 or more pre-retirement stages. In some embodiments, coke formation conditions are avoided in the pre-reforming stages by modifying the temperature of the gaseous hydrocarbon vapor stream and / or by modifying the composition of the gaseous hydrocarbon vapor stream by heating and partially reforming it. to avoid such conditions. Additionally, in some embodiments, the preform stages provide a reformer current to the first stage of reform that avoids the conditions of metal dust and coke formation. Reforming vapor reformer in one or more reformer stages to form a syngas stream and a flue gas stream may be performed as described elsewhere herein including controlling the heated fuel stream supplied to the stages. individual. For example, in some embodiments, reforming may be performed at one or more reformer stages, each stage comprising i) heating the reformer stream by recovering heat from a heated air stream to form a heated reformer stream and a stream. (ii) reforming at least a portion of the heated reformer stream and (iii) combustion of a portion of a heated fuel stream in the presence of cooled air stream to form the heated air stream for the next stage. Preferably, the reformer stream has a combination of temperature and composition that avoids the conditions of metal dust and coke formation through all stages of the reformer.

In some embodiments, a gaseous hydrocarbon vapor reforming apparatus comprises: a) a fuel preheater that partially combines the fuel into a first fuel and air mixture to form a heated fuel stream, the heated fuel stream being in a reformer module; b) an air preheater combining a second fuel and air stream in the presence of an air stream to form a heated air stream, the heated air stream supplying heat to the reformer module; and c) a reformer module for forming a syngas stream from a reformer stream. The fuel and air preheaters may comprise any suitable catalytic combustion chamber and may comprise a separate catalytic reactor or may comprise a modified tube section that has been loaded with structured or unstructured catalyst. In general, catalytic combustion involves catalytic oxidation of the combustible components in the heat relevant stream as a result of the highly exothermic oxidation reaction. The combustion reaction may be catalyzed using any suitable catalyst and / or may include or comprise non-catalytic combustion in conjunction with an ignition source or a flame source for initiation.

In some embodiments, the reformer module may comprise one or more, such as 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 8 or more, 9 or more or 10 or more. more pre-retirement stages. In some embodiments, the reformer module may comprise from 2 to 10, 3 to 8, or 4 to 7 pre-reform stages. After the pre-retirement stages, the reformer module may comprise from 1 to 40 stages of reformer, such as 2 to 35 stages, 3 to 30 stages, 5 to 25 stages, 8 to 20 stages, or 10 to 15 stages of reformer. Each preforming stage may comprise at least one heat exchanger and at least one preforming bed. Any suitable heat exchanger and catalytic preform bed may be used.

In some embodiments, the one or more pre-reformer stages may comprise a PCR. The PCR may be configured similarly to a printed circuit heat exchanger ("PCHE") as known in the art, with catalytic chambers or beds intermittently located within the flow path of the gaseous hydrocarbon vapor stream. such that the current may be heated alternately in a heat exchanger or heat exchange part and then partially catalytically reformed in a catalytic chamber or bed in a series of pre-reform stages. In this regard, the PCR may comprise a series of plates having one or multiple channels for the gaseous hydrocarbon vapor stream fluid and the flue gas stream in proximity to each other for heat exchange. The channels for the individual streams may be etched or otherwise formed into separate plates, which may then be stacked and diffused together or otherwise joined in a heat exchanger configuration such that the channels are brought close to one another. another and heat is exchanged through the channel walls. Stacking may include stacking end plates, joining plates and specific gaseous hydrocarbon stream configurations and flue gas plates according to the desired heat transfer. The channels in each plate can be configured for single pass or multiple pass heat transfer between currents, and when formed in a PCR can be configured to operate in simultaneous flow, cross flow or counter flow. In some embodiments, plates for one stream may be configured for multiple passes, while plates for the other stream are configured for single passes.

Each of the gaseous hydrocarbon vapor plates and flue gas plates may include multiple bed penetrations or pre-reforming catalyst chamber, so that when the plates are stacked and joined in a heat exchanger configuration, the plates form multiple heat exchange zones, where heat is exchanged from the flue gas channels within the gaseous hydrocarbon stream vapor channels, and multiple reform zones, where the heated gaseous hydrocarbon vapor stream is partially reformed from catalytic form. Reform zones may be formed by alignment of the pre-reform catalytic chamber or bed penetrations when the plates are stacked to form the chambers in which the catalyst may be located, supported or not supported. In this regard, in some embodiments, the PCR may operate as follows: the gaseous hydrocarbon vapor stream may enter the gaseous hydrocarbon vapor stream plate channels of the PCR, where it may be heated by the hot stream, which may be the flue gas stream from the reformer stages flowing into the flue gas plate channels. Upon heating, the gaseous hydrocarbon vapor stream plate channels may direct the gaseous hydrocarbon vapor stream into a pre-reform chamber or catalyst-containing bed in which the gaseous hydrocarbon vapor stream may be partially catalytically reformed. . After being partially reformed, the gaseous hydrocarbon vapor stream may proceed into the plate channels further along the plate, where the current will be reheated by the flue gas flowing in the flue gas plate channels of the flue gas plate. combustion. Thus, partial reforming may include multiple heating and partial reforming interactions in a single structure comprising end plates, limit plates, one or more flue gas plates, and hydrocarbon-gas vapor plates.

After the pre-reformer stages, the reformer module can comprise from 1 to 40 reformer stages, such as from 2 to 35 stages, 3 to 30 stages, 5 to 25 stages, 8 to 20 stages, or 10 stages. to 15 stages of catalytic reform. The reformer module can be configured in any suitable manner to convert the reformer current leaving the pre-reformer stages into syngas. Such reforming may include one or more heat exchangers that heat the reformer stream by recovering heat from a hot stream, such as a heated air stream. The hot stream may provide sufficient heat to the reformer stream to promote reform in one or more of the catalytic reform beds. Reform beds may catalytically reform the reformer current in an endothermic reaction, thereby cooling the reformer current, the reformer current may then be reheated by heat recovery from a heat stream, such as a heated air stream. and then can be directed to one or more of the additional reformer beds. In this way the steps can be repeated through the stages of the reformer.

In some embodiments, the reformer module may comprise multiple stages, where each stage includes i) a heat exchanger that heats the reformer stream recovering heat from a heated air stream to form a cooled air stream, ii) a bed (i) a combustion chamber combining a portion of a heated fuel stream to reheat the cooled air stream.

In some embodiments, the apparatus may include a fuel distribution control network that is configured to passively control the amount of heated fuel stream that is supplied to each combustion chamber in the reformer stages. This configuration can be achieved by designating the appliance and the individual heat exchange and appliance reformer components to balance pressure drops in air and fuel currents throughout the appliance to supply the proper amount of air and fuel for each chamber. combustion in the reformer stages. In some embodiments, the fuel distribution control network is configured to supply an amount of heated fuel stream to one or more second stage reformer combustion chambers and subsequent stages that is less than the amount of heated fuel stream supplied to one or more of the previous stages. In some embodiments, the fuel distribution control network is configured to supply an amount of heated fuel stream for each of the second stage reformer combustion chambers and subsequent stages that is less than the amount of heated fuel stream supplied to each other. the previous stage.

As with pre-retirement stages, in some embodiments, reformer stages may comprise a PCR. In some embodiments, the PCR that creates the reformer stages may consist of end plates, boundary plates, air flow plates, fuel flow plates, and reformer current plates. Each of the active plates may include flow channels for the relevant supply stream (air, fuel or reformer), multiple catalytic combustion chamber penetrations and multiple catalytic reforming bed penetrations. When combined in a stack and diffused or otherwise joined, the multiple catalytic combustion layer penetrations and multiple catalytic reforming bed penetrations of each plate may be aligned with the corresponding penetrations of the other plates in the stack to form multiple chambers. of catalytic combustion and multiple catalytic reforming beds.

In some embodiments, such a printed circuit reactor may operate as follows. A heated air stream flows through the flow channels of the air flow plates and heat exchanges with the reformer current flowing through the reformer plate flow channels to heat the reformer current and cool the air stream. . The reformer stream then enters the first catalytic reform bed, where it is catalytically reformed into an endothermic reaction, cooling the reformer stream and converting a portion of the stream into syngas. The cooled air stream proceeds to the first catalytic combustion chamber where it is joined by a portion of the heated fuel stream which is catalytically combated to reheat the air stream. The reheated air stream then exchanges heat with the cooled reformer stream and the process can be repeated through the multiple stages. In some embodiments, the portion of the heated fuel stream is supplied parallel to each of the combustion chambers. In some embodiments, each combustion chamber is supplied with the same amount of fuel from the heated fuel stream. Preferably, the amount of heated fuel stream supplied to each of the combustion chambers after the first combustion chamber is reduced relative to the previous combustion chamber. Preferably, the heated fuel stream supply is passively controlled. Finally, the stream leaving the reformer module comprises a syngas stream formed from the reformer stream and a flue gas stream comprising the air stream, any residual fuel components and the fuel combustion components.

In some embodiments, the stream reforming apparatus of a gaseous hydrocarbon may additionally include at least one heat exchanger that recovers heat from the swim stream after it leaves the reformer module. In some embodiments, the apparatus comprises at least two heat exchangers for recovering heat from a portion of the syngas stream. In some embodiments, at least one of the at least one heat exchangers is a cooled heat exchanger. The cooled heat exchanger may comprise a heat exchanger that is submerged in water. A portion of hot syngas may enter the cooled heat exchanger at a temperature and / or above the metal dusting temperatures and may be cooled to a temperature below the metal dusting conditions. Since the heat exchanger is submerged in water, the heat exchanger never sees metal dusting conditions as the water temperature remains essentially constant as it boils and as a result of the high heat transfer coefficient. from boiling water the metal of the submerged heat exchanger will remain essentially at the boiling temperature of the water. The steam produced by cooling the syngas stream in this way can be combined with a gaseous hydrocarbon stream prior to entering the reformer module. Although the cooled exchanger avoids metal dusting conditions, a portion of the syngas tubing adjacent the inlet to the cooled exchanger may undergo metal dusting conditions, so the apparatus part is preferably constructed from from materials resistant to metal dust formation or from material coated with a metal during resistant coating and / or is configured for easy repair and / or removal and replacement. The submerged heat exchanger is preferably a SHPP that relies on a thermosyphon effect to exchange heat from the syngas stream into water, circulating water through the exchanger as a result of density differences between boiling water and water. single phase. The PCHE may comprise one or more syngas plates and one or more water plates which together may be the "active" plates within the exchanger. Syngas cards may have multiple stream channels recorded or otherwise provided through which syngas flows. Water plates may have multiple recorded or otherwise provided flow channels through which water / steam flows. Water and syngas plates, along with limit plates and / or end plates can be stacked in a heat exchanger configuration. In that configuration, PCHE may comprise a series of stacked and otherwise joined or stacked plates having multiple channels for the flow of syngas and water streams close together to exchange heat from syngas streams to water streams. PCHE can be formed by stacking end plates, limit plates, and specific syngas and water current plate configurations according to the desired heat transfer. The channels in each plate may be configured for single-pass or multiple-pass heat transfer between currents, and when formed within a heat exchanger may be configured to operate in simultaneous flow, cross flow or reverse flow. Preferably, the heat exchanger formed from the plate is configured to flow simultaneously to prevent drying in the water side passages of the exchanger. In some embodiments, the plates for one of the chains may be configured for multiple passes, while the plates for the other chains are configured for single passes. The water level in the cooled exchanger may be controlled using any suitable method such as the known water level control device for the control of boiling water levels. The submerged heat exchanger may be partially or completely submerged provided that sufficient water is present to ensure that metal dusting conditions are avoided in the heat exchanger. In some embodiments, the heat exchanger gives rise to the volume of the stream for combination with the gaseous hydrocarbon stream.

In some embodiments, at least one of the heat recovery heat exchangers of the syngas stream comprises a heat recovery heat exchanger. In some embodiments, the syngas heat recovery heat exchanger exchanges heat from the syngas stream into at least one selected stream from: one or more air streams, one or more fuel streams, one or more water streams and one or more gaseous hydrocarbon streams. In some embodiments, the syngas heat recovery heat exchanger comprises a multi-stream heat exchanger. The syngas heat recovery heat exchanger may comprise a multi-stream heat exchanger which is a multi-stream PCHE. The multi-stream PCHE may comprise one or more syngas plates and one or more reagent fed plates, which together may be active plates within the exchanger. Syngas cards may have multiple stream channels recorded or otherwise provided on them through which syngas flows. Reagent feed plates may have multiple flow channels etched or otherwise provided therethrough the various reagent feeds flow. For example, in some embodiments, reagent feed plates may have one or more flow channel sets for one or more air streams, one or more flow channel sets for one or more fuel streams, one or more flow channel sets for one or more gaseous hydrocarbon streams and / or one or more flow channel sets for one or more water streams. Syngas and reagent feed plates, along with limit plates and / or end plates can be stacked in a heat exchanger configuration. In such a configuration, PCHE may comprise a series of stacked and diffused joined or otherwise joined plates having multiple channels for the flow of syngas streams into the reagent feed streams. Stacking may include endplate stacking, boundary plates, and specific syngas and reagent feed plate configurations according to the desired heat transfer. The channels in each plate may be configured for single-pass or multi-pass heat transfer between currents, and when formed in a heat exchanger may be configured to operate in simultaneous flow, cross flow or reverse flow. Preferably, the syngas heat recovery heat exchanger operates in the reverse flow or in a multi-pass cross flow approximation of the counter flow to maximize heat recovery from the syngas stream. In some embodiments, the plates for one or some of the chains may be configured for multiple passes, while the plates for one or some of the other chains are configured for single passes.

In some embodiments, the at least one syngas stream heat recovery heat exchangers comprises a cooled heat exchanger and a syngas heat recovery heat exchanger.

In some embodiments, the apparatus comprises at least one heat exchanger that recovers heat into a water stream from a flue gas stream after the flue gas stream leaves the reformer module. In some embodiments, such heat exchanger comprises a PCHE as described elsewhere herein, where the active PCHE plates are one or more of the flue gas plates and one or more of the water plates. In some embodiments, such as those in which the reformer module is rotated in a reduced reform temperature mode or a higher pressure reform mode, the flue gas stream may be preheated prior to entering the SHP to exchange the heat with the water current. Such preheating may include catalytic combustion of a part of at least one fuel stream or a part of at least one gaseous hydrocarbon stream in the presence of the flue gas stream. Catalytic combustion may be conducted in a flue gas preheater which may be configured in substantially the same manner as the air preheater discussed above. The flue gas preheater can be used to heat the flue gas to provide increased heat to the water stream, thereby increasing the vapor-to-carbon ratio that is ultimately fed to the reformer module and promoting a balance. more favorable for the reforming reaction at a given pressure and temperature, making the flue gas preheater an attractive option for lower temperature and higher pressure reformer modules. In some embodiments, especially those where a high hydrogen concentration is desired in the syngas stream, the apparatus may include a water and gas change reactor. The water and gas change reactor can promote catalytic hydrogen production according to equation (6). The water and gas change reactor preferably receives the syngas current at a temperature sufficiently below the metal dust formation temperatures that the reactor outlet equilibrium temperature is also below the metal dust formation temperatures. In some embodiments, multiple water and gas change reactors may be used in series to further increase the hydrogen content of the syngas stream. The water and gas change reactor may be similar to a catalytic combustion chamber and may comprise a separate catalytic reactor or may comprise a modified section of pipe that has been loaded with structured or unstructured catalyst, and which may preferably include a catalytic catalyst. Precious metal suitable.

In some embodiments, the apparatus is configured to prevent or reduce metal dust formation and coke formation conditions on all heat exchangers, pre-reform stages, reform stages, and water and gas change reactors. inside the device.

In some embodiments, the gaseous hydrocarbon vapor reforming apparatus comprises: a) a syngas heat recovery heat exchanger that recovers heat from a syngas stream to heat at least one air stream; b) an air flow divider that divides the air stream into a first air stream and a second air stream, the first air stream connecting to a fuel stream to form a fuel and air mixture; c) a fuel flow divider that divides the fuel and air mixture into a first fuel and air stream and a second fuel and air stream, the first fuel and air stream connecting to a fuel preheater and the second stream fuel and air by connecting to an air preheater; d) a fuel preheater partially combining the fuel in the first fuel and air stream to form a heated fuel stream; e) an air preheater combining the second fuel and air stream in the presence of the second air stream to form a heated air stream; f) a preformer partially reforming a gaseous hydrocarbon stream heated in the presence of steam to form a reformer vapor; g) a reformer reforming the reformer stream to form a syngas stream; h) a cooled exchanger that recovers heat from the syngas stream to form or assist in the formation of steam from a water stream to the preformer.

Some embodiments of the apparatus will now be described in detail with reference to the figures. It should be understood that the detailed apparatuses are by way of example only and that various modifications and changes to the apparatuses may be made without departing from the scope of the processes and apparatuses defined herein as understood by those skilled in the art. Examples of such changes may include, but are not limited to, the type and number of reagent streams, the type and number of each of the heat exchangers and combustion chambers / preheaters, the type, number and configurations of pre-reform stages and reforming, construction materials, heat exchanger and piping configurations and sizes, valve placement and type, stream temperatures and pressures, flow rate and compositions of various streams, type and number of water and gas change reactors if any and types of catalyst and their compositions.

Referring to Figure 1a, in some embodiments, a gaseous hydrocarbon vapor reforming system or apparatus 100 may include at least four reagent feed streams: a gaseous hydrocarbon feed stream 102, a fuel feed stream 104, an air supply stream 106 and a water supply stream 108. The gaseous hydrocarbon feed stream 102 may feed any gaseous hydrocarbon stream suitable for steam reforming, including natural gas, methane, propane or other gaseous hydrocarbons, mixtures of gaseous hydrocarbons, refinery gases and other combustion gases and mixtures or combinations thereof in system 100. Preferably, the gaseous hydrocarbon feed stream 102 is sufficiently low in impurity (such as sulfur) to provide reforming and / or acceptable gas and water change catalyst life. In some embodiments, the gaseous hydrocarbon feed stream 102 is natural gas or methane. The gaseous hydrocarbon feed stream 102 may enter reforming system 100 at any suitable temperature and pressure for the system. Preferably, the pressure is at or above the syngas stream pressure 180 leaving the reformer module 150. In some embodiments, the gaseous hydrocarbon feed stream 102 enters system 100 at a pressure between 1 mPa (10 bar) and 10 mPa (100 bar), such as between 1 mPa to 9 mPa (10 bar and 90 bar), between 1 mPa to 7.5 mPa (10 bar and 75 bar), between 1 mPa to 6 mPa (10 bar and 60 bar) bar), between 1 mPa and 5 mPa (10 bar and 50 bar), between 1 mPa and 4 mPa (10 bar and 40 bar), between 1 mPa and 3 mPa (10 bar and 30 bar), between 1 MPa and 2 mPa (10 bar and 20 bar), between 1 mPa and 18 mPa (10 bar and 18 bar), between 1.1 mPa to 1.7 mPa (11 bar and 17 bar), between 1.2 mPa and 1.6 mPa (12 bar and 16 bar), between 1.3 mPa and 1.5 mPa (13 bar and 15 bar) or between 1.35 mPa and 1.45 mPa (13.5 bar and 14.5 bar). In some embodiments, the gaseous hydrocarbon feed stream 102 enters system 100 at any suitable temperature, such as the supply temperature or ambient temperature, but preferably above the dew point temperature for the stream. In some embodiments, the gaseous hydrocarbon feed stream 102 enters system 100 at a temperature between about -40 ° C and 250 ° C, such as between -25 ° C and 200 ° C, between -10 ° C and 150 ° C. Between -10 ° C and 100 ° C, between 0 ° C and 90 ° C, between 0 ° C and 75 ° C, between 5 ° C and 65 ° C, between 10 ° C and 50 ° C, between 15 ° C to 40 ° C, between 15 ° C and 35 ° C, between 20 ° C and 30 ° C or between 20 ° C and 25 ° C. The fuel feed stream 104 may be any combustion fuel feed stream suitable for steam reforming processes, such as exhaust gas streams or end of a pressure change adsorption (PSA) process, from from a methanol production process or from an ammonia production process and may include or be enriched with other fuel components such as a gaseous hydrocarbon stream, or streams such as natural gas streams, methane streams, streams propane, mixtures of gaseous hydrocarbons, refinery gases or other combustion gases and mixtures or combinations thereof. In some embodiments, a portion of the gaseous hydrocarbon feed stream 102 or another gaseous hydrocarbon feed stream may be provided as at least a part of the fuel feed stream 104. In some embodiments, the fuel feed stream 104 may include hydrocarbons. residual gases and / or hydrogen from syngas 192 stream after downstream processing. Fuel supply stream 104 may enter reforming system 100 at any temperature and pressure suitable for the system. In some embodiments, such as embodiments in which the fuel feed stream 104 comprises a PSA off gas or final stream, the fuel feed stream 104 enters system 100 at a pressure of less than 1 mPa, such as less than 800 less than 500 kPa, less than 2500 kPa, less than 100 kPa, less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 7.5 kPa. In some embodiments, such as when the fuel feed stream 104 comprises a methanol synthesis purge, the fuel feed stream 104 may enter the system at a pressure that is substantially higher, in which case the pressure may be scaled. downward using any suitable means to gradually reduce the pressures of the gas stream. In some embodiments, the fuel feed stream 104 enters system 100 at any suitable temperature, such as the supply temperature or ambient temperature, but preferably above the dew point of the stream. In some embodiments, the fuel feed stream 104 enters system 100 at a temperature of from -40 ° C to 350 ° C, such as from -30 ° C to 300 ° C, from -20 ° C to 250 ° C, between -10 ° C and 200 ° C, between -5 ° C and 150 ° C, between 0 ° C and 100 ° C, between 0 ° C and 50 ° C, between 5 ° C and 40 ° C, between 10 ° C to 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. Air supply stream 106 may be any suitable air supply stream, such as a forced air supply stream or a compressed air supply stream, which provides sufficient oxygen for combustion processes within the reforming system 100. In some embodiments, the air supply stream may be enriched with additional oxygen or may be purified to remove or limit the presence of one or more gaseous or particulate components or contaminants. In some embodiments, the air supply stream 106 enters system 100 at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less and 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 7.5 kPa. In some embodiments, the air supply stream 106 enters system 100 at any suitable temperature, such as the supply temperature or ambient temperature, but preferably above the melting point temperature of the stream. In some embodiments, the air supply stream 106 enters system 100 at a temperature of from -40 ° C to 350 ° C, such as from -30 ° C to 300 ° C, from -20 ° C to 250 ° C, between -10 ° C and 200 ° C, between -5 ° C and 150 ° C, between 0 ° C and 100 ° C, between 0 ° C and 50 ° C, between 5 ° C and 40 ° C, between 10 ° C to 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. Water supply stream 108 may be any suitable water supply stream and may be an untreated, treated, purified or conditioned water stream. Preferably, the water has been treated to meet at least the heater feed water standards suitable for operating temperatures and pressures to avoid residue formation within the heat exchanger and / or excessive solids formation. In some embodiments, the water feed stream 108 may have been heated above room temperature in a water heater prior to entering the process. In some embodiments, the water supply stream 108 may comprise out-of-process steam, in which case it may be directly mixed with the gaseous hydrocarbon stream 102 shortly before entering the reformer module 150, in which case the configuration of the hydrocarbon stream may be directly mixed with the gaseous hydrocarbon stream 102. Heat exchange for Figure 1a can be changed. Preferably, all necessary steam is generated within the process from the water stream 108 without any steam export from the process or import into the process. In some embodiments, the water supply stream 108 enters system 100 at any suitable pressure above the syngas stream pressure 180 leaving the reformer module, such as between 1 mPaa and 10 mPaa, such as between 1 mPaa and 9 mPaa. between 1 mPaa and 7.6 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa, or between 1.35 mPaa and 1.45 mPaa. In some embodiments, the water supply stream 108 enters system 100 at any suitable temperature, such as the supply temperature or ambient temperature. In some embodiments, the water feed stream 108 enters system 100 at a temperature just above freezing and below boiling, such as between 0.1 ° C and 350 ° C, between 2.5 ° C and 250 ° C. , between 5 ° C and 150 ° C, between 10 ° C and 125 ° C, between 15 ° C and 100 ° C, between 15 ° C and 75 ° C, between 15 ° C and 50 ° C, between 15 ° C and 40 ° C, between 15 ° C and 35 ° C, between 20 ° C and 30 ° C or between 20 ° C and 25 ° C. The water supply stream 108 may be preheated in the heat exchanger 109 which may be separated from or may be part of the syngas heat recovery heat exchanger 110. In some embodiments, the heat exchanger 109 is combined with the heat exchanger. 110 heat recovery heat recovery in a single PCHE.

One or more of the reagent feed streams, such as 2 to 10, 3 to 9, or 4 to 6 reagent feed streams, or 2, 3, 4, 5, 6, 7, 8, 9 or 10 reagent feed streams, may be preheated in one or more syngas heat recovery heat exchangers 110. In some embodiments, at least one air feed stream, such as air feed stream 106 or stream 108 is preheated in the heat exchanger 110. In some embodiments and as illustrated, the heat exchanger 110 may be a multi-stream heat exchanger where more than one reagent feed stream is preheated.

In some embodiments, including the embodiment as illustrated in Figure 1a, the fuel feed stream 104 may be optionally divided through the fuel stream divider 133 into fuel feed stream 105 and flue gas feed stream 112 prior to syngas heat recovery heat exchanger 110. Both streams 105 and 112 may then be heated in syngas heat recovery heat exchanger 110. Alternatively, fuel supply stream 104 may be split after leaving the heat exchanger 110, but preferably before combining with the combustion air stream 114. The fuel feed stream 104 may be divided using any suitable flow-dividing means before or after the heat recovery heat exchanger. 110, such as the "T" or "Y" pipe connection, and can be split to divert fuel fuel stream 104 through the combustion gas fuel stream 112 for combustion in the presence of the combustion gas stream 160 to provide additional heat to the water supply stream 108. The fuel stream divider 113 may be a pipe joint or any other suitable flow dividing mechanism, may include a valve 113a as illustrated, or other suitable dividing device for controlling the flow of fuel, may be split and flow controlled using passive means maintaining the ratio. desired downstream air / fuel supply to feed the fuel preheater 120, air preheater 122, and flue gas preheater 175 over a wide range of flow magnitudes. Such passive means may include controlling flow path geometry based on pressure drops and a desired Reynolds number range within the relevant flow path.

Similarly, in some embodiments, including the embodiment as illustrated in Figure 1A, the air supply stream 106 may be divided into air supply stream 107 and combustion air stream 114 prior to the inlet of the recovery heat exchanger. syngas 110 through the air flow divider 115. Both streams 107 and 114 can then be heated on the syngas 110 heat recovery heat exchanger. In some embodiments, the heat exchanger 110 is configured such that the current combustion air flow 114 combine with the fuel feed stream 105 in the heat exchanger 110 to form the fuel and air mixture flow 118 before entering the heat exchanger. Alternatively, the air supply stream 106 may be divided after leaving the exchanger 110. The air flow divider 115 may be any suitable means of dividing the air supply stream 106 before or after the heat exchanger. heat recovery from syngas 110, such as a "T" or "Y" pipe fitting, provided that the combustion air stream 114 connects with the fuel feed stream 105 before the fuel and air flow divider 116 Air flow divider 115 diverts sufficient air from air supply stream 106 through combustion air stream 114 into fuel supply stream 105, preferably before fuel and air flow divider 116 to form a fuel and air mixture stream 118 having sufficient air for partial combustion of fuel from the fuel feed stream 105 in the fuel preheater 120. Air flow divider 115 may be a pipe joint or any other suitable flow dividing mechanism, may include a valve 115a as illustrated, or other suitable dividing and control device, or air flow may be divided and controlled using passive means that maintain the desired downstream fuel-to-air ratio to feed the fuel preheater 120 and air preheater 122 over a wide range of flow magnitudes. Such passive means may include controlling flow path geometry based on pressure drops and a desired Reynolds number range within the relevant flow paths. The syngas heat recovery heat exchanger 110 can be any suitable heat exchanger and can heat exchange between hot and cold inlet streams using simultaneous flow, counter flow and cross flow heat exchange. Preferably, the syngas heat recovery heat exchanger is a PCHE and heat exchange using the counter flow heat exchange or an opposite flow heat exchange approach utilizing the multi-pass cross flow exchange in one flow direction. otherwise general. In some embodiments, the syngas heat recovery heat exchanger recovers heat from the syngas stream prior to leaving the reformer system 100 for further processing, such as, for example, in a pressure balance adsorption system, a membrane separation system, a methanol production system, or an ammonia production system. The syngas heat recovery heat exchanger 110 may recover heat from the syngas stream 190 to preheat one or more reagent feed streams, including one or more gaseous hydrocarbon streams, one or more fuel streams, one or more air currents, and / or one or more water currents. In order to prevent or reduce the formation of metal dust, the syngas stream 190 preferably enters the heat exchanger 110 at a temperature which is below the metal dusting temperature. Preferably, the syngas stream 190 leaves heat exchanger 110 at a temperature and pressure suitable for any further downstream processing.

In some embodiments, the syngas heat recovery heat exchanger 110 may comprise a PCHE which is constructed from a series of plates as illustrated in figures 2a-c. The plates may be combined in a stack and diffused or otherwise joined together to provide heat exchange between the hot and cold inlet currents. In general, the flow paths for each of the streams may be formed on the plates by embossing, grinding, or other suitable process and may be configured to provide the desired heat exchange, while limiting the pressure drop to one or more streams through. of the heat exchanger. Preferably, the inlet syngas stream 190 is below the metal dusting temperatures thereby ensuring that metal dusting conditions are avoided within the syngas heat recovery heat exchanger 110.

Referring to Figures 2a-c, in some embodiments, the syngas heat recovery heat exchanger 110 may comprise one or more limiting plates 210, one or more syngas plates 230, and one or more reagent feed plates 260 In the embodiment illustrated in Figures 2a-c, the plates together with the appropriate end plates (not shown), when properly stacked and formed in a heat exchanger, will form a syngas heat recovery heat exchanger 110 which includes heat exchanger 109. Each of the plates may be constructed from materials suitable for the purposes and conditions present in the exchanger 110. Examples of materials suitable for plate construction 210, 230 and 260 include 316 stainless steel and 304 stainless steel and The plates may independently have the thicknesses described in Table 1. In some embodiments, the plates may be 1.6 mm. of thickness. Figure 2a illustrates a boundary plate 210 having a syngas flow path 211 comprising at least one flow channel 212 connecting syngas inputs 213 with syngas outputs 214. Limit plates 210 ensure that all power cards 260 reagent plates have hot current plates on either side, a limit plate 210, or a syngas plate 230 and help balance heat load and heat flow throughout the weight of the stack. Boundary plate 210 may have one or more independent flow channels 212, which with adjacent projections, may be sized to provide safe pressure containment and an inexpensive combination of heat transfer capability and pressure drop. In some embodiments, independent flow channels 212 may each comprise a generally semicircular cross section and may have dimensions as described in Table 1. In some embodiments, independent flow channels 212 may each have a cross section. semicircular with a width of about 1.95 mm, a depth of about 1.10 mm. and about 0.4 mm. of overhang. Although a specific number of independent flow channels 212 is illustrated, it should be understood that the syngas flow path 211 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system.

While Figure 2A illustrates the syngas flow path 211 as a multipath flow path, the flow path 211 may also comprise a direct forward flow, simultaneous flow, cross flow or single pass flow comprising multiple channels. independent. In some embodiments the syngas flow path 211 may comprise more than one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 100 passages, from 5 to 75 passages, from 10 to 60 passages, from 15 passages. 50 passes or 20 to 40 passes. Preferably, the syngas flow path 211 comprises a multi-circuit flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages, or 30 or more passages where The passages are cross-flow during heat exchange and where syngas flows in a generally counter-flow direction with respect to flows on the reagent feed plate 260. Boundary plate 210 also includes air feed current penetrations 215 and 216, combustion air stream penetration 217, fuel feed stream penetration 218, fuel and air mixture stream penetration 227, combustion gas fuel stream penetrations 219 and 220, feed stream penetrations of gaseous hydrocarbon 221 and 222, stream penetrations of syngas 223 and 224 and water stream penetrations 225 and 226.

Referring to Figure 2b, the syngas board 230 includes syngas inputs 231, syngas outputs 232, and syngas flow path 233. The syngas flow path 233 may comprise one or multiple syngas independent flow channels 233. syngas flow path 233 may comprise one or more syngas 234 independent flow channels. Channels 234 and adjacent projections may be sized to provide safe pressure containment and a cheap combination of heat transfer capability and pressure drop. . In some embodiments, syngas independent flow channels 234 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 234 may each have a semicircular cross section with a width of about 1.95 mm, a depth of about 1.10 mm. and 0.4 mm. of overhangs. Although a specific number of independent flow channels 234 is illustrated, it should be understood that the syngas flow path 233 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system.

Although figure 2b illustrates the syngas flow path 233 as a multipath flow path, the flow path 233 may also comprise a direct forward flow path, a simultaneous flow, a cross flow or a single pass flow comprising multiple independent channels. In some embodiments, the syngas flow path 233 may comprise more than one passage, each passage comprising a single reversal in the flow direction, such as from 2 to 100 passes, from 5 to 75 passes, from 10 to 60 passes, 15 to 50 passes, or 20 to 40 passes. Preferably, the syngas flow path 233 comprises an opposite flow flow path which may be approximated by a multi-pass flow path having 5 or more passages, 10 or more passages, 15 or more passages, 20 or more passages. more, 25 passages or more or 30 passages or more where the passages are cross-flow during heat exchange, but syngas flows in a generally cross flow or counter-flow with respect to air, fuel and gaseous hydrocarbon flows on the reagent feed plate 260. The syngas plate 230 also includes air feed current penetrations 235 and 236, combustion air current penetration 237, fuel feed current penetration 238, mixture mix current penetration. fuel and air 247, flue gas fuel stream penetrations 239 and 240, gaseous hydrocarbon feed stream penetrations 241 and 242 syngas stream penetrations 243 and 244 and water stream penetrations 245 and 246.

Referring to Figure 2c, the reagent feed plate 260 has a water flow path 261 which connects the water flow inputs 262 and the water flow outputs 263 as shown at the bottom left of the feed plate. 260. The water stream flow path 261 may comprise one or multiple independent flow channels 264. That portion of the reagent feed plate 260 when formed in a heat exchanger corresponds to the water flow streams for the heat exchanger 109 as shown in figure 1a. The 264 flow channels and adjacent projections can be sized to provide safe pressure containment and an inexpensive combination of heat transfer capability and pressure drop. In some embodiments, independent flow channels 254 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 264 may each have a cross section. semicircular with a width of about 1.90 mm., a depth of about 1.10 mm., and about 0.4 mm. of overhangs. Although a specific number of independent flow channels 264 is illustrated, it should be understood that water stream flow path 261 may comprise any suitable number of independent flow channels properly configured to the individual needs of the system. .

Although Figure 2c illustrates the water flow stream path 261 as a multipath flow path, flow path 261 may also comprise a direct forward flow path, a simultaneous flow, a cross flow, or a flow path. comprising multiple independent channels. In some embodiments the water flow stream path 261 may comprise more than one passage, each passage comprising a single reversal in the flow direction, such as from 2 to 100 passes, from 5 to 75 passes, from 10 to 60 passes, from 15 to 50 passes or from 20 to 40 passes. Preferably, the water flow stream path 261 comprises a multipass flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages, or 30 or more passages. where the passages are in reverse flow during heat exchange, but flow in a direction generally contrary to the flow with respect to the flow of the syngas stream. Reagent feed plate 260 also includes air supply flow path 265 with air supply inlet 266 and air supply output 267, combustion air supply flow path 268 with input 269, the fuel feed flow path 270 with the fuel feed inlet 271 and the fuel and air mixture outlet 272, the flue gas fuel flow path 273 with the inlet flue gas fuel flow 274 and flue gas fuel outlet 275 and gaseous hydrocarbon flow path 276 with gaseous hydrocarbon inlet 277 and gaseous hydrocarbon outlet 278. Each of the flow paths 265, 268, 270 273 and 276 may comprise one or multiple independent flow channels 279, 280, 281,282 and 283, respectively. In general, each of the independent flow channels 279, 280, 281, 282 and 283 and adjacent protrusions can be sized to provide safe pressure containment and a cheap combination of heat transfer capability and pressure drop. In some embodiments, independent flow channels 279, 280, 281, 282, and 283 may each independently comprise a generally semicircular cross-section and may each independently have the dimensions described in Table 1. In some embodiments. In both embodiments, independent flow channels 279, 280, 281, 282 and 283 may each have a semicircular cross section with a width of about 1.90 mm, a depth of about 1.10 mm. and about 0.4 mm. of overhangs. In some embodiments, the inlet and outlet portions of the independent flow channels 283 may each have a semicircular cross section with a width of about 1.75 mm, a depth of about 1.00 mm. and 0.5 mm. of overhangs. Although a specific number of independent flow channels 279, 280, 281,282 and 283 are illustrated, it should be understood that flow paths 265, 268, 270, 273 and 276 can independently comprise any suitable number of flow channels. independently configured to suit individual system needs.

Although Figure 2c illustrates flow paths 265, 268, 270, 273, and 276 as direct cross flow or single pass flow paths, in some embodiments flow paths 265, 268, 270, 273, and 276 may comprise independently more than one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 20 passes, 2 to 10 passes or 2 to 5 passes. Preferably, the flow paths 265, 268, 270, 273 and 276 each comprise a single or single pass cross flow flow path. In Figure 2c, the combustion air flow path 268 is configured to provide the combustion air stream mixture 114 of Figure 1a, with the fuel feed stream 105 within the exchanger 110 directing the air flowing through the path. 268 and the fuel flowing in the flow path 270 to the same outlet, the fuel and air mixture outlet 272. When configured in this manner, there is no separate union of these streams downstream of the heat recovery heat exchanger. syngas heat 110 as shown in Figure 1a. Reagent feed plate 260 also includes air feed stream penetrations 285 and 286, combustion air stream penetration 287, fuel feed stream penetration 288, fuel and air mixture stream penetration 289, penetrations of flue gas fuel stream 290 and 291, gaseous hydrocarbon feed stream penetrations 292 and 293, syngas stream penetrations 294 and 295 and water stream penetrations 296 and 297.

In some embodiments, the plates used to form the syngas heat recovery heat exchanger embodiments 110 may be stacked and diffused or otherwise joined in any suitable order to form a heat exchanger. In some embodiments, the plates may be stacked and joined by diffusion or by other means in the following order: at least one end plate (not shown), 1 boundary plate 210, multiple heat exchange cells, each heat cell. heat exchange comprising a reagent feed plate 260 followed by a syngas plate 230, an additional reagent feed plate 260, a boundary plate 210, and at least one end plate (not shown). Accordingly, in some embodiments the order of the printed circuit heat exchange plates in a given stack may have the following pattern (end plate = "E", limit plate 210 = "B", reagent feed plate 260 = "R", syngas power board 230 = "S"): EBRSRSR S ... RSRB E. Endplates can be blank plates without any flow path circuitry and can be insulated to improve Heat transfer and heat loss limit. End plates can serve as caps for chambers and flow access paths formed by the alignment of the penetrations and current support connection relevant to the heat exchanger 110, such as through doors or heads in fluid connection with the chambers. and flow paths. Accordingly, the endplates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors and heads. In some embodiments, a single end plate is used for each end of the exchanger 164, where the end plate is thicker than the other plates. In other embodiments, multiple endplates may be used at each end to provide sufficient thickness to support or provide the heads or doors.

In some embodiments, the syngas heat recovery heat exchanger 110 comprises from 5 to 30 heat exchange cells, such as 7 to 25, 8 to 20, 9 to 17 or 10 to 15 exchange cells. each heat exchange cell comprising a reagent feed plate 260 and a syngas plate 230 In preferred embodiments for reforming 2 natural gas SCMHs using off-gas PSA as fuel, the recovery heat exchanger syngas heat exchanger 110 comprises at least 14 heat exchange cells. In a preferred embodiment, the syngas gas recovery heat exchanger 110 comprises 2 limit plates 210, 14 heat exchange cells and an additional reagent feed plate 260 and 5 end plates and comprises plates each having one, 1.65 mm. in thickness providing a stack that is 57.75 mm. high. The number of heat exchange plates and cells can be modified according to production needs, heat exchange efficiency, number of supply currents and other parameters.

When the various plates are stacked and joined by diffusion or other means to form a heat exchanger, preferably the various corresponding penetrations in each plate are aligned to form flow access paths or chambers for the various reagent feeds. In some embodiments, air feed stream penetrations 215, 235 and 285 and 216, 236 and 286 are aligned to form access flow paths or chambers through which air feed stream 107 may be supplied to and may exit, respectively, from the heat exchanger reagent feed plates 260. In some embodiments, the combustion air stream penetrations 217, 237, and 287 are aligned to form the access flow paths or chambers through which the combustion air stream 114 can be supplied to the reagent feed plates 260. of the heat exchanger. In some embodiments, the fuel feed stream penetrations 218, 238, and 288 are aligned to form access flow paths or chambers through which the fuel feed stream 105 may be supplied to the reagent feed plates 260. of the heat exchanger. In some embodiments, the fuel and air mixture stream penetrations 227, 247 and 289 are aligned to form the access flow paths or chambers through which the fuel feed stream 108 in combination with the combustion air stream. 114 may exit the heat exchanger reagent feed plates 260. In some embodiments, flue gas feed stream penetrations 219, 239 and 290 and 220, 240 and 291 are aligned to form access flow paths or chambers through which flue gas fuel stream 112 can be supplied to and may exit, respectively, from the heat exchanger reagent feed plates 260. In some embodiments, the gaseous hydrocarbon feed stream penetrations 221, 241 and 282 and 222, 242 and 293 are aligned to form the access flow paths or chambers through which gaseous hydrocarbon feed stream 102 can be supplied. stops and can exit the heat exchanger reagent feed plates 260 respectively. In some embodiments, the syngas 213, 231 and 294 and 224, 244 and 295 gas stream penetrations are aligned to form the access flow paths or chambers through which the syngas stream 190 may be supplied to and may exit, respectively of the syngas plates 230 and heat exchanger limit plates 210. In some embodiments, the water feed stream penetrations 225, 245 and 277 and 226, 246 and 296 are aligned to form the access flow paths or chambers through which the water feed stream 108 may be supplied to and may exit, respectively, from the heat exchanger reagent feed plates 260.

In addition to the alignment of the various penetrations, the stacking of the plates preferably places the independent channels that create flow paths 265, 268, 270, 273 and 276 in proximity to the independent channels that create flow paths 211 and / or 233 to facilitate heat transfer between the relevant currents through the respective independent channel walls.

In operation, the gaseous hydrocarbon stream 102 may enter the syngas heat recovery heat exchanger 110 essentially at the pressure and temperature entering the reformer system 100 and may leave the exchanger 110 at a pressure between 1 mPaa and 10 mPaa, such as 1 mPaa to 9 mPaa, 1 mPaa to 7.5 mPaa, 1 mPaa to 6 mPaa, 1 mPaa to 5 mPaa, 1 mPaa to 4 mPaa, 1 mPaa to 3 mPaa, 1 mPaa to 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa, or between 1.35 mPaa and 1.45 mPaa and at a temperature between 200 and 375 ° C, such as between 225 ° C and 375 ° C, between 250 ° C and 370 ° C, between 275 and 365 ° C, between 300 and 360 ° C or between 325 ° C and 355 ° C Preferably, the temperature of stream 102 leaving the syngas heat recovery heat exchanger 110 is between 100 ° C of syngas stream temperature 190, such as between 90 ° C, 80 ° C, 70 ° C, 60 ° C. ° C, 50 ° C, 40 ° C, 30 ° C or 20 ° C Preferably, the pressure drop to the gaseous hydrocarbon stream 102 through the exchanger 110 is less than 50 kPa (0.50 bar), such as, for example, less than 40 kPa (0.40). bar), less than 30 kPa (0.30 bar), less than 20 kPa (0.20 bar) or less than 10 kPa (0.10 bar).

In some embodiments, the fuel feed stream 105 may enter the syngas heat recovery heat exchanger 110 at a pressure of less than 1 kPa, such as less than 800 kPa, less than 500 kPa, less than 250 kPa, 100 kPa, less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, or less than 7.5 kPa. In some embodiments, the fuel feed stream 105 enters the syngas heat recovery heat exchanger 110 at any suitable temperature, such as the supply temperature or ambient temperature. In some embodiments, the fuel feed stream 105 enters the syngas heat recovery heat exchanger 110 at a temperature of between -40 ° C and 350 ° C, such as between -30 ° C and 300 ° C, between -20 ° C to 250 ° C, -10 ° C to 200 ° C, -5 ° C to 150 ° C, 0 ° C to 100 ° C, 0 ° C to 50 ° C, 5 ° C C and 40 ° C, between 10 ° C and 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. In some embodiments, the fuel supply stream 105 may leave the exchanger 110 at a pressure of less than 10 kPa, such as less than 800 kPa, less than 500 kPa, less than 250 kPa, less than 100 kPa, less than 75 kPa. , less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 75 kPa, and at a temperature between 200 ° C and 375 ° C, as 225 to 375 ° C, 250 to 370 ° C, 275 to 365 ° C, 300 to 360 ° C, or 325 to 355 ° C. Preferably, the temperature of the stream 105 leaving the syngas heat recovery heat exchanger 110 is within 100 ° C of the syngas stream temperature 190, such as between 90 ° C, 80 ° C, 70 ° C, 60 ° C. ° C, 50 ° C, 40 ° C, 30 ° C or within 20 ° C of the syngas 190 vapor temperature. Preferably, the pressure drop to the fuel feed stream 105 through the exchanger 110 is less than 10 ° C. bar, such as less than 9 bar, less than 7 bar, less than 6 bar or less than 5 bar. The flue gas fuel stream 112 may enter the syngas heat recovery heat exchanger 110 at a pressure of less than 1 kPa, such as less than 800 kPa, less than 500 kPa, less than 250 kPa, less than 100 less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, or less than 7.5 kPa and at any appropriate temperature, such as as at the supply temperature or ambient temperature, or at a temperature of from -40 ° C to 350 ° C, such as from -30 ° C to 300 ° C, from -20 ° C to 250 ° C, from -10 ° C to 200 ° C, between -5 ° C and 150 ° C, between 0 ° C and 100 ° C, between 0 ° C and 50 ° C, between 5 ° C and 40 ° C, between 10 ° C and 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. In some embodiments, the flue gas fuel stream 112 may leave the exchanger 110 at a pressure of less than 1 mPa, such as less than 800 kPa, less than 500 kPa, less than 250 kPa, less than 100 kPa, less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 75 kPa, and at a temperature between 200 ° C and 375 ° C, such as between 225 ° C and 375 ° C, between 250 ° C and 370 ° C, between 275 and 365 ° C, between 300 and 360 ° C, or between 325 ° C and 355 ° C. Preferably, the temperature at stream 112 leaving the syngas heat recovery heat exchanger 110 is within the range of 100 ° C of the syngas stream temperature 190, such as within 90 ° C, 80 ° C, 70 ° C, 60 ° C, 50 ° C, 40 ° C, 30 ° C or within 20 ° C of syngas stream temperature 190. Preferably, the pressure drop to the combustion gas fuel stream 112 through the exchanger 110 is less than 100 bar, such as less than 9 bar, less than 7 bar, less than 6 bar, or less than 5 bar. The combustion air stream 114 may enter the syngas heat recovery heat exchanger 110 at a pressure of less than 1 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 7,5 kPa and at any suitable temperature, such as at the supply temperature or room temperature, or at a temperature between -40 ° C and 350 ° C, such as between -30 ° C and 300 ° C, between -20 ° C and 250 ° C, between -10 ° C and 200 ° C, between -5 ° C and 150 ° C, between 0 ° C 100 ° C, between 0 ° C and 50 ° C, between 5 ° C and 40 ° C, between 10 ° C and 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. In some embodiments, the combustion air stream 114 may leave the exchanger 110 at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa. less than 15 kPa, less than 10 kPa or less than 7,5 kPa and at a temperature between 200 ° C and 375 ° C, such as between 225 ° C and 375 ° C, between 250 ° C and 370 ° C, between 275 and 365 ° C, between 300 and 360 ° C or between 325 ° C and 355 ° C. Preferably, the temperature of stream 114 leaving the syngas heat recovery heat exchanger 110 is within 100 ° C of the syngas stream temperature 190, such as within 90 ° C, 80 ° C, 70 ° C, 60 ° C, 50 ° C, 40 ° C, 30 ° C or within 20 ° C of the syngas stream temperature 190. Preferably, the pressure drop to the combustion air stream 114 through the exchanger 110 is less than 10 bar, such as less than 9 bar, less than 7 bar, less than 6 bar or less than 5 bar. The air supply stream 107 may enter the syngas heat recovery heat exchanger 110 at a pressure of less than 1 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 7,5 kPa and at any suitable temperature, such as at supply temperature or room temperature, or at a temperature between -40 ° C and 350 ° C ° C, such as between -30 ° C and 300 ° C, between -20 ° C and 250 ° C, between -10 ° C and 200 ° C, between -5 ° C and 150 ° C, between 0 ° C and 100 ° C, between 0 ° C and 50 ° C, between 5 ° C and 40 ° C, between 10 ° C and 35 ° C, between 15 ° C and 30 ° C or between 20 ° C and 25 ° C. In some embodiments, the air supply stream 107 may leave the exchanger 110 at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa. less than 15 kPa, less than 10 kPa or less than 7,5 kPa and at a temperature between 200 ° C and 375 ° C, such as between 225 ° C and 375 ° C, between 250 ° C and 370 ° C, between 275 and 365 ° C, between 300 and 360 ° C, or between 325 ° C and 355 ° C. Preferably, the temperature of the stream 107 leaving the syngas heat and recovery heat exchanger 110 is within 100 ° C of the syngas stream temperature 190, such as within 90 ° C, 80 ° C, 70 ° C, 60 ° C, 50 ° C, 40 ° C, 30 ° C or within 20 ° C of the temperature of the syngas stream 190. Preferably, the pressure drop for the air supply stream 107 through the exchanger 110 is less than 10 kPa, such as less than 9 kPa, less than 7 kPa, less than 6 kPa or less than 5 kPa. The syngas stream 190 may enter the syngas 110 heat recovery heat exchanger at a temperature of between 200 ° C and 450 ° C, such as between 300 ° C and 420 ° C, between 325 ° C and 400 ° C. , between 350 ° C and 400 ° C, between 375 ° C and 400 ° C, between 385 ° C and 400 ° C, or between 385 ° C and 395 ° C and at a pressure below the pressure of syngas 180 which leaves the reformer module 150, such as between 1 mPaa and 10 mPaa, between 1 mPaa and 9 mPaa, between 1 mPaa and 75 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, 1 mPaa to 3 mPaa, 1 mPaa to 2 mPaa, 1 mPaa to 1.8 mPaa, 1.1 mPaa to 1.7 mPaa, 1.2 mPaa to 1.6 mPaa, 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa and may leave exchanger 110 at a temperature of between 75 ° C and 200 ° C, between 100 ° C and 180 ° C, between 125 ° C and 170 ° C , or between 130 ° C and 150 ° C and at a pressure between 1 mPaa and 10 mPaa, such as between 1 mPaa and 9 mPaa, between 1 mPaa and 7.5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa. Preferably, the pressure drop to the syngas stream 114 through the exchanger 110 is less than 50 kPa, such as, for example, less than 40 kPa, less than 30 kPa, less than 20 kPa or less than 1 mPa. The syngas stream 191 leaving the syngas heat recovery heat exchanger 110 may proceed to the heat exchanger 109, where it may heat exchange with the water stream 108. Preferably, the heat exchanger 109 is combined with the exchanger 110 heat in a single PCHE The syngas stream may enter heat exchanger 109 (as a part of heat exchanger 109 or separately) at the temperature and pressure with which it has left heat exchanger 110 and may leave heat exchanger 109 to a temperature between 75 ° C and 200 ° C, between 100 ° C and 180 ° C, between 125 ° C and 170 ° C or between 130 ° C and 150 ° C and at a pressure of between 10 mPaa and 100 mPaa, 1 mPaa to 9 mPaa, 1 mPaa to 7.5 mPaa, 1 mPaa to 6 mPaa, 1 mPaa to 5 mPaa, 1 mPaa to 4 mPaa, 1 mPaa to 3 mPaa, 1 mPaa to 2 mPaa , between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1 , 45 mPaa. Preferably, water stream 108 leaves heat exchanger 109 within 20 ° C of the temperature of syngas stream 191. Water stream 108 may enter heat exchanger 109 (as a part of heat exchanger 110 or separately) essentially at the same temperature and pressure as you entered system 100 and you can leave heat exchanger 109 at a temperature between 95 ° C and 200 ° C, such as between 110 ° C and 190 ° C, between 115 ° C and 180 ° C between 120 ° C and 170 ° C or between 130 ° C and 150 ° C and at a pressure equal to or above the current pressure 180 leaving the reformer module 150, such as between 1 mPaa and 10 mPaa, between 1 mPaa and 9 mPaa, between 1 mPaa and 7.5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa to 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa . The combustion air stream 114 may be combined with the fuel feed stream 105 within the syngas heat recovery heat exchanger 110 or after leaving the heat exchanger 110 as illustrated in Figure 1a to form a mixing stream. fuel and air flow 118 and a fuel and air mix flow stream 118 may be divided through the fuel and air flow divider 116 into a preheated fuel mix 119 and a preheated air mix 117. The fuel flow divider and air 116 may be a pipe joint or any other suitable flow dividing mechanism, and may include a valve, or other suitable dividing device for controlling the flow or the fuel and air flow may be split and the flow controlled using a passive means maintaining the desired downstream air and fuel ratio for fuel preheater 120 and air preheater 122 across a wide range of flux magnitudes. Alternatively, in some embodiments, details of the configuration of the fuel and air streams entering and leaving the syngas heat recovery heat exchanger and proceeding to the preheaters may appear as in Figure 1b. Figure 1b illustrates fuel supply stream 105, combustion air stream 114, and air supply stream 107 entering a portion of syngas heat recovery heat exchanger 110. In figure 1 b, combustion air stream 114 does not match fuel feed stream 105 prior to entering fuel preheater 120 and instead joins fuel preheat stream 119a, which is not a mixture of air and fuel in that embodiment in preheater 120. In such a case, the fuel feed stream 105 may be divided into air preheat fuel stream 117a and fuel preheat stream 119a, without any air including combustion air stream 114, and the fuel stream 117a may be fed as a pure fuel stream in the air preheater 122. In such a case, the details of the resistance network and the equi pressure limbs in figure 15 will be slightly different. In some embodiments, such as embodiments in which the hydrogen and carbon monoxide content of the fuel streams is sufficient for catalytic combustion, preheaters 120 and 122 may be configured to mix the incoming pure fuel and air streams prior to combustion. pass the mixed stream into the catalyst beds or chambers for catalytic combustion. Alternatively, preheaters 120 and 122 may be configured with a starting ignition source, such as a spark source or a heating element, to provide non-catalytic (homogeneous) combustion of all or at least part of the ignition current. fuel. In such cases, at least part of the non-catalytic combustion would need to occur in a diffusion flame, while part of the non-catalytic combustion could occur in a premixed flame. Preheaters can also be configured for non-catalytic combustion and catalytic combustion of the fuel stream.

Referring to Figure 1a, the fuel preheat mixture 119 may be partially catalytically combined in the fuel preheater 120 to provide heat for fuel stream reforming 124. The fuel preheater 120 may be any suitable catalytic combustion chamber in which The fuel in the fuel preheat mixture 119 is partially catalytically blown, and may comprise a separate catalyst reactor loaded with structured or unstructured catalyst or may comprise a modified section of the tube that has been loaded with structured or unstructured catalyst. In some embodiments, the fuel in the preheated fuel mixture 119 is only partially catalyzed, since the amount of air in the preheated fuel mixture 119 is deliberately insufficient to completely combuste the fuel. In preferred embodiments, where the preheated fuel mixture 119 entering the fuel preheater 120 is below the metal dusting temperatures and the reformer fuel stream 124 is above the metal dusting temperatures, the conditions for Metal dust formation may occur on the fuel preheater 120, and therefore the fuel preheater 120 is preferably constructed from metal dust-resistant metal or from metal coated with a dust-resistant coating. and / or is configured to perform quick repair, removal and / or replacement.

Preferably, the preheated fuel mixture 119 is at a temperature below the metal powder formation conditions such as at a temperature below 400 ° C, such as below 375 ° C, below 360 ° C, below 350 ° C, below 325 ° C, or below 300 ° C. Preferably, the pressure of the preheated fuel mixture 119 is less than 1 mPa, such as less than 800 kPa, less than 500 kPa, less than 250 kPa, less than 100 kPa, less than 7.5 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa or less than 7.5 kPa. Preferably, the amount of air in the preheated fuel mixture 119 is only sufficient when fully consumed in excessive fuel to provide the required reformer fuel temperature without any additional reactor control being required.

Preferably, the reformer fuel stream 124 is at a temperature above the metal dusting conditions, such as at a temperature above 775 ° C, 780 ° C, above 785 ° C, above 790 ° C, above 795 ° C, above 800 ° C, above 805 ° C, above 810 ° C, or above 815 ° C. Preferably, the reformer fuel stream pressure 124 is less than 10 kPa, such as less than 8 kPa, less than 5 kPa, less than 2.5 kPa, less than 1 kPa, less than 0.75 kPa, less than 0.5 kPa, less than 0.4 kPa, less than 0.3 kPa, less than 0.2 kPa, less than 0.15 kPa, less than 0.10 kPa, or less than 0.075 kPa or less than 0, 05 kPa. The preheated air mixture 117 may be combusted in the preheater 122 in the presence of the air supply stream 107 to form the reforming air stream 126. The air preheater 122 may be any suitable catalytic combustion chamber in which the fuel in the preheated air mixture 117 is catalytically combined and may comprise a separate catalyst reactor loaded with structured or unstructured catalyst or may comprise a modified section of the tube that has been loaded with structured or unstructured catalyst. Unlike fuel preheater 120, the fuel in the preheated air mixture 117 is completely or substantially completely catalytically mixed since the amount of air in the air preheater 122 is not limited to conserving further downstream combustion fuel. In preferred embodiments, where the preheated air mixture 117 enters the fuel preheater 122 is below the metal dusting temperatures, and the reformer airflow 126 is above the metal dusting temperatures, Metal dust formation may occur on preheater 122, and therefore air preheater 122 is preferably constructed from metal dust-resistant metal or from metal coated with a metal dust-resistant coating. and / or is configured to perform easy repair, removal or replacement. By locating the occurrence of metal dusting conditions or limitation of components within the reformer system 100 that are exposed to the metal dusting conditions, the cost of the system and the ease of use and repair / maintenance. can be minimized.

In general, the preheated air mixture 117 is at a temperature below the metal dusting conditions, such as at a temperature below 400 ° C, such as below 375 ° C, below 360 ° C, below 350 ° C, below 325 ° C, below 300 ° C. Preferably, the pressure of the preheated air mixture 122 is less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than 7,5 kPa, or less than 5 kPa. Preferably, the amount of fuel in the preheated air mixture 117 is only sufficient when fully exhausted in excess air to provide the required reformer air temperature without any additional reactor control being required. The air supply stream 107 may enter air preheater 122 at essentially the temperature and pressure at which it leaves the syngas heat recovery heat exchanger 110, such as at a temperature below the metal dusting conditions. and may leave the air preheater 122 as the reformer air stream 126 at a temperature above the metal dusting conditions, such as at a temperature above 800 ° C, above 815 ° C, above 830 ° C, above 840 ° C, above 850 ° C, above 860 ° C, above 875 ° C, above 890 ° C, or above 900 ° C. Preferably the reformer airstream pressure 126 is less than 1 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than 7,5 kPa, or less than 5 kPa. As illustrated in Figure 1a, after leaving the syngas heat recovery heat exchanger 110, the flue gas fuel stream 112 is combined with the flue gas stream 160 from the reformer module 150 to form the fuel-containing flue gas stream 162. The fuel-containing flue gas stream 162 is combusted in the flue gas preheater 175 by catalytic combustion of the fuel components in the fuel-containing flue gas stream 162, forming the current Alternatively, the flue gas fuel stream 112 may directly feed the flue gas preheater 175, where it may mix with the flue gas stream 160 and then be combusted to form the gas stream. The combustion gas stream 163 can provide additional heat to the water 108 in heat exchanger 164 after water stream 108 leaves heat exchanger 109. Thereafter the heated flue gas stream 163 may be exhausted as flue gas or may proceed for further downstream processing. The flue gas preheater 175 may be any suitable catalytic combustion chamber in which the fuel in the fuel containing flue gas stream 162 (or in the fuel stream 112, when the fuel stream 112 connects directly with the flue gas preheater). 175) is catalytically combined to provide heat to the fuel-containing flue gas stream 162 and may comprise a separate catalyst reactor loaded with structured or unstructured catalyst or may comprise a modified tube section that has been loaded with structured or unstructured catalyst . Preferably, the fuel-containing flue gas stream 162 enters the flue gas preheater 175 at a temperature of between 200 ° C and 450 ° C, such as between 225 ° C and 440 ° C, between 250 and 425 ° C, between 275 and 420 ° C, between 300 and 410 ° C, between 325 and 400 ° C, or between 350 and 390 ° C and a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than 7.5 kPa, or less than 5 kPa and leave the flue gas preheater 175 as flue gas stream heated to a temperature between 250 and 550 ° C, such as between 275 and 525 ° C, between 300 and 500 ° C, between 350 and 490 ° C, between 375 and 475 ° C, or between 400 and 450 ° C C, and at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than at 7,5 kPa or less than 5 kPa. Heat exchanger 164 may be any heat exchanger suitable for exchanging heat from the heated flue gas stream 163 within water stream 108. In some embodiments, heat exchanger 164 may be a PCHE. In some embodiments, heat exchanger 164 may comprise a SHP which is constructed from a series of plates as illustrated in figures 3a-b. The plates may be combined into a stack and diffused or otherwise joined together to form heat exchanger 164 to provide heat exchange between the incoming hot and cold streams. In general the flow paths for each of the streams may be formed on the plates by engraving, grinding or other suitable process and may be configured to provide the desired heat exchange while limiting the pressure drop to one or more currents through the exchanger. of heat. Preferably, streams in and out of exchanger 164 are maintained under conditions of temperature, pressure and composition that prevent or reduce the conditions of metal dust formation within the heat exchanger.

Referring to FIGS. 3a-b, in some embodiments, heat exchanger 164 may comprise one or more water supply plates 320 and one or more heated flue gas plates 350. Each plate may be constructed from suitable materials for purposes and conditions present in exchanger 164. Examples of suitable materials for the construction of plates 320 and 350 include 316 stainless steel and 304 stainless steel. Water feed plates 320 and heated flue gas plates 350 may have independently of the thicknesses described in Table 1. In some embodiments, the plates may each be 16 mm. of thickness. Figure 3a illustrates the flue gas flow plate 350 with the heated flue gas stream flow path 351, which connects the heated flue gas stream inputs 353 and the heated flue gas stream outputs 356. The heated flue gas inlets 353 may divide the heated flue gas stream 163 into multiple independent flow channels 355 comprising the heated flue gas stream flow path 351. The heated flue gas stream outputs 356 can re-combine flow in flow channels 355 to reform flue gas stream 163 as it leaves heat exchanger 164. Heated flue gas stream inlets 353 and hot flue gas stream outlets 356 connect to the hot flue gas stream inlet penetration 358 and hot flue gas stream outlet penetration 357 and the heated flue gas flow 350 also includes water inlet penetration 354 and water outlet penetration 352. Flow channels 355 and adjacent projections can be sized to provide safe pressure containment and an economical combination of transferability heat and pressure drop. In some embodiments, independent flow channels 355 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 355 may each have a cross section. semicircular with a width of about 1.9 mm, a depth of about 1.0 mm, and about 0.4 mm. of overhangs. Although a specific number of independent flow channels 355 is illustrated, it should be understood that water stream flow path 351 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system.

Although Figure 3a illustrates the heated flue gas stream flow path 351 as a direct cross flow or single pass flow path, in some embodiments the heated flue gas stream flow path 351 may comprise more than one pass, each pass comprising a unique reversal in the flow direction, such as from 2 to 20 passes, 20 to 10 passes, or from 2 to 5 passes. Preferably, the heated flue gas stream flow path 351 comprises a direct cross flow or single pass flow path during heat exchange flows in a reverse flow direction with respect to the general flow of the water stream. Figure 3b illustrates water supply plate 320 having a water flow path 321 that connects with water flow inputs 326 and water flow outputs 323. Water flow path 312 may comprise one or multiple independent flow channels 325. Water streams 326 and water streams 323 connect with water inlet penetration 324 and water outlet penetration 322, respectively, and the water supply plate. 320 also includes heated flue gas stream outlet penetration 327 and heated flue gas stream input penetration 328. Flow channels 325 and adjacent projections may be sized to provide safe pressure containment and a combination cheap heat transfer capability and pressure drop. In some embodiments, independent flow channels 325 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 325 may each have a cross section. semicircular with a width of about 1.63 mm., a depth of about 0.75 mm. and about 0.4 mm. of overhangs. Although a specific number of independent flow channels 325 is illustrated, it should be understood that water stream flow path 321 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system. While Figure 3b illustrates water flow stream path 321 as a multi-pass single channel flow path, flow path 321 may also comprise the forward direct flow, simultaneous flow, cross flow or single pass flow comprising multiple independent channels. In some embodiments, the water stream flow path 321 may comprise more than one passage, each passage comprising a single reversal in the flow direction, such as from 2 to 100 passes, 5 to 75 passes, 10 to 60 passes, 15 50 passes or 20 to 40 passes. Preferably, the water stream flow path 312 comprises a multipass flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages, or 30 or more passages. where the passages are in cross flow during the heat exchange, and where the water stream flows in a direction generally contrary to the flow with respect to the heated flue gas stream.

In some embodiments, the plates used to form heat exchanger embodiments 164 may be stacked and diffused joined or otherwise joined in any suitable order to form heat exchanger 164. In some embodiments, the plates may be stacked and joined together diffused or otherwise joined in the following order: at least 1 end plate (not shown), multiple heat exchange cells, each heat exchange cell comprising a heated flue gas flow plate 350 followed by a water stream feed plate 320, followed by a final heated flue gas flow plate 350, and then at least one end plate (not shown). Accordingly, the order of the printed circuit heat exchange plates in a given stack for heat exchanger 164 may have the following pattern (end plate = "E", flue gas plate 350 = "F", plate current flow rate 320 = "W"): EFWFFWFFW F ... FWFFWFE). End plates may be blank plates without any flow path circuitry and may be insulated to improve heat transfer and limit heat loss. End plates can serve as caps for penetrations and support the connection of currents relevant to heat exchanger 164, such as through doors or heads. Accordingly, the end plates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors or heads. In some embodiments, a single end plate is used for each end of exchanger 164, where the end plate is thicker than the other plates. In other embodiments, multiple endplates may be used at each end to provide sufficient thickness to support or provide the heads or doors. In some embodiments, heat exchanger 164 may comprise a stack that is between 50 mm. and 70 mm. in height, such as 60 mm. high. In some embodiments, heat exchanger 164 comprises from 2 to 30 heat exchange cells, such as 5 to 25, 7 to 20, 8 to 17, or 10 to 15 heat exchange cells, each heat exchanger cell. heat exchange comprising a heated flue gas flow plate 350 followed by a water stream feed plate 320, followed by a heated flue gas flow plate 350. In preferred embodiments for reforming 1 SCMH of gas using off-gas PSA as fuel, heat exchanger 164 comprises at least 10 heat exchange cells. In a preferred embodiment, heat exchanger 164 comprises 10 heat exchange cells, each heat exchange cell comprising a heated flue gas flow plate 350 followed by a water stream feed plate 320, and comprises a 350 additional heated flue gas flow plate, and six end plates for a total of 30 active plates. The number of heat exchange plates and cells can be modified according to production needs, heat exchange efficiency and other parameters.

When the various plates are stacked and diffused joined or other means to form a heat exchanger, the heated flue gas stream inlet penetrations 358 and the heated flue gas stream outlet penetrations 357 are preferably aligned. with the heated flue gas stream inlet penetrations 328 and the heated flue gas stream outlet penetrations 327 in the water supply plates 320 to form inlet and outlet flow access paths or chambers for the heated flue gas stream. Additionally, the water stream inlet penetrations 324 and 356 and the water stream outlet penetrations 322 and 355 are also preferably aligned to form the inlet and outlet flow pathways or chambers for the water stream. Stacking the plates also preferably places flow paths 321 and 351 in close proximity to each other to facilitate heat transfer between streams through independent channel walls 325 and 355.

In some embodiments, the water stream 108 may enter the heat exchanger 164 at essentially the same temperature and pressure as the syngas heat recovery heat exchanger 110 and may leave the heat exchanger 164 at a temperature of between 120 ° C and 210 ° C, such as between 130 and 205 ° C, between 150 and 200 ° C, or between 175 and 195 ° C and at a pressure of between 1 mPaa and 10 ara, such as between 1 mPaa and 9 mPaa, between 1 mPaa and 7.5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa , between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa. Preferably, the pressure drop to the water stream 108 through the heat exchanger 164 is less than 100 kPa, such as less than 75 bar, less than 60 bar, less than 50 bar, less than 40 bar or less than 30 bar. . The heated flue gas stream 163 may enter the heat exchanger 164 at essentially the same temperature and pressure that left the flue gas preheater 175 and may leave the heat exchanger 164 at a temperature of between 120 ° C and 200 ° C, such as such as between 125 and 180 ° C, between 130 and 160 ° C, or between 140 and 150 ° C and a pressure of less than 2 kPa, such as less than 1.5 kPa or less than 1 kPa.

After leaving heat exchanger 164, water stream 108 may enter cooled heat exchanger 165 where it may be further heated to raise the current for the reforming process. The cooled heat exchanger 165 may comprise the water submerged heat exchanger 166 in a tank or vial. The cooled heat exchanger 165 may be used to cool the syngas cooling stream 170. The syngas cooling stream 170 may be a part of the syngas stream 180 leaving the reformer module 150. The syngas stream 180 may be divided using the syngas current divider 184 to form the syngas cooling current 170 and syngas current 182. syngas current divider 184 may be any suitable means of dividing syngas current flow 180 such as “T” and Ύ ”piping connection and can direct the desired amount of flow in each direction to ensure proper steam production in the cooled heat exchanger 165 and adequate hydrogen production in the optional gas and water change reactor 186 or suitable temperature and pressure of the syngas entering the syngas heat recovery heat exchanger 110. Preferably, the cooled heat exchanger 165 and the callus exchanger 166 are configured such that the cooled stream flow of syngas 170 remains turbulent throughout the desired reduction range in which system 100 is operated.

As long as heat exchanger 166 remains submerged in water in cooled exchanger 165, metal dusting conditions are avoided in the exchanger since the temperature of the exchanger never rises above the boiling point of water, as the water temperature remains essentially constant during phase transition. Although avoided in the cooled heat exchanger 165, metal dust formation conditions may occur in the adjacent syngas cooled stream 170 to cool the heat exchanger 165, and therefore a portion of syngas 170 cooling stream is It is preferably constructed from metal dust resistant metal or metal coated with a metal dust resistant coating and / or is configured for easy repair, removal and / or replacement. Ideally, the portion of the syngas 170 cooling stream that is exposed to metal dusting conditions is minimized and is configured to minimize repair, maintenance and replacement. In some embodiments, the conditions of metal dust formation within the stream 170 are preferably limited to 5 pipe diameters from the inlet to the cooled heat exchanger 165 and thus the pipe in this part of the system may be constructed of metal. Metal Dust Resistant or metal coated with a metal dust resistant coating and / or is configured for easy repair, removal and replacement. In this way steam can be lifted from the hot syngas to be used for the reforming stages, while the metal dust formation conditions are located in a small part of the syngas 170 cooled stream. The cooled heat exchanger 165 also comprises steam and water output 168. Steam formed in cooled heat exchanger 165 may pass through steam outlet 167 and proceed into system 100. Dump water and dissolved solids may be periodically driven through the water outlet 168 by actuating valve 169 to prevent or limit buildup in the cooled heat exchanger 165. The heat exchanger 166 may be partially or completely submerged in water from the water stream 108 after leaving heat exchanger 164. The exchanger 166 and the heat it transfers from the cooled stream from syngas 170 to water preferably generates the volume of steam used in the module. the reformer 150. In some embodiments, the heat exchanger 166 may be a PCHE. In some embodiments, heat exchanger 166 may comprise a SHP which is constructed from a series of plates as illustrated in Figure 4a-d. The plates may be combined in a stack and diffused or otherwise joined together to form heat exchanger 166 to provide the heat exchange between incoming hot and cold streams. In general, the flow paths for each of the streams may be formed on the plates by engraving, grinding or other suitable process and may be configured to provide the desired heat exchange, while limiting the pressure drop to one or more streams across the plate. heat exchanger. Preferably, streams in and out of exchanger 166 are maintained under conditions of temperature, pressure and composition that prevent or reduce the conditions of metal dust formation within the heat exchanger.

Referring to FIGS. 4a-d, in some embodiments, heat exchanger 166 may comprise one or more water plates 410, one or more syngas chilled current plates 420, one or more upper end plates 430 and one or more lower end plates 440. Each plate may be constructed from materials suitable for the purposes and conditions present in exchanger 166. Examples of materials suitable for plate construction 320 and 350 include 316 stainless steel and 304 stainless steel. The plates may independently have the thicknesses described in Table 1. In some embodiments, the plates may each be 1.6 mm. of thickness. Figure 4A illustrates water plate 410 having a water flow path 411 that connects water flow inputs 412 and water flow outputs 413. Water flow inputs 412 can divide water flow. on one or more independent flow channels 414 forming flow path 411. Water stream outputs 413 may re-combine flow channels 414 to exit heat exchanger 166. Flow channels 414 may be configured for boiling thermosyphon of water within the exchanger 166 and may be formed in any suitable shape and size. In some embodiments, independent flow channels 414 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 414 may each have a cross section. semicircular with a width of about 2.6 mm., a depth of about 1.10 mm., and 0.4 mm. of overhangs. Although a specific number of independent flow channels 414 is illustrated, it should be understood that water stream flow path 411 may comprise any number of independent flow channels configured appropriately to the individual needs of the system.

In some embodiments, water stream inlets 412 and outlets 413 may also comprise a generally semicircular cross section having a width of about 0.6 mm. 3.5 mm., a depth of 0.3 to 1.75 mm., and projections of 0.3 to 1.5 mm. and may be sized in the same or different manner as independent flow channels 414. In some embodiments, inlets 412 and outlets 413 each have a semicircular cross-section with a width of about 2.6 mm. about 1.10 mm., and 0.4 mm. of overhangs. Although Figure 4a illustrates water flow path 411 as a direct counter flow or simultaneous flow path or single pass flow path, in some embodiments water stream flow path 411 may comprise more than one. one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 20 passes, from 2 to 10 passes or from 2 to 5 passes. Preferably, the water flow path 411 comprises a simultaneous flow path and single or direct passage. As illustrated in Figure 4a, the water flow plate 410 also includes the cooled current inlet and outlet penetrations of syngas 415 and 416, respectively.

Referring to Figure 4b, the syngas chilled current plates 420 may have a syngas chilled current flow path 421, which connects the syngas 422 chilled current input penetrations and the syngas 423 chilled current output penetrations. The syngas chilled current input penetrations 422 may feed the input channels 426, which may be further divided to form one or multiple independent flow channels 424 that create the flow path 421. The syngas cooled current output 423 may recombine multiple output channels 425 which can recombine independent flow channels 424 to exit the heat exchanger. Inlet and outlet channels 426 and 425 and independent flow channels 424 may each comprise a generally semicircular cross section and may have the dimensions described in Table 1. In some embodiments, independent flow channels 424 may have, each a semicircular cross section with a width of about 1.99 mm., a depth of about 1.10 mm., and 0.4 mm. of overhangs. In some embodiments, the inlet and outlet channels 426 and 425 may each have a semicircular cross section with a width of about 2.2 mm, a depth of about 1.10 mm. and 0.4 mm. of overhangs. Although a specific number of independent flow channels 414 is illustrated, it should be understood that water stream flow path 411 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system.

Although Figure 4b illustrates the syngas chilled current flow path 421 as a single pass or simultaneous or direct opposite flow path, in some embodiments, the syngas chilled current flow path 421 may comprise more than one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 20 passes, from 2 to 10 passes or from 2 to 5 passes. Preferably, the syngas chilled current flow path 421 comprises a direct flow or single pass simultaneous flow path.

In some embodiments, the plates used to form heat exchanger embodiments 166 may be stacked and diffused joined or otherwise joined in any suitable order to form the heat exchanger. In some embodiments, the plates may be stacked and diffused or otherwise joined in the following order: at least one upper end plate 430 (Figure 4c), multiple heat exchange cells, each heat exchange cell comprising a water plate 410 followed by a syngas chilled current flow plate 420, with an additional water plate and then at least one lower end plate 440 (Figure 4d). Accordingly, the order of the printed circuit heat exchange plates in a given stack for heat exchanger 166 may have the following pattern for the active heat exchanger plates 166; (water plate 410 = "W"; syngas 420 = S chilled current plate): WSWSWS ... WSWS W. In some embodiments, the configuration will comprise syngas 420 water plate cells and chilled current plates alternated with an additional water plate 410 to serve as a junction plate for the last syngas 420 chilled current plate in the stack. End plates may be blank plates without any flow path circuitry and may be insulated to improve heat transfer and limit heat loss. In some embodiments, multiple endplates may be used at each end. The end plates provide a wall for the joint plate facing the end plate, serve as caps for penetrations and support the connection of the relevant currents to the heat exchanger 166, such as through doors and heads . Accordingly, the end plates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors and the heads. In some embodiments, a single end plate is used for each end of the exchanger 166, where the end plate is thicker than the other plates. In other embodiments, multiple endplates may be used at each end to provide sufficient thickness to support or provide the heads or doors. In some embodiments, heat exchanger 166 may comprise a battery that is between 15 and 25 mm. high.

In some embodiments, the upper end plate 430 may include a syngas current input penetration 432 and a syngas current output penetration 431 for the syngas cooled current input and output. When the various plates are stacked and joined by diffusion or otherwise to form a heat exchanger, syngas current input penetrations 432 and syngas current output penetrations 431 are preferably aligned with current input penetrations. 422 and the syngas 423 chilled current output penetrations into the syngas 420 chilled current plates and the syngas 414 and 415 chilled current inlet and outlet penetrations to form the paths 410 of inlet and outlet flow access or chambers for the syngas cooled current. Stacking the plates also preferably places flow paths 411 and 421 in close proximity to each other to facilitate heat transfer between streams through the walls of the independent channels 414 and 424. For plates and streams which do not have penetrations through the channels. In which flow paths and flow channels are accessed, heads may be attached, such as by welding, through the individual channel ends to facilitate the distribution and / or collection of current flowing through the relevant channels.

In some embodiments, heat exchanger 166 comprises from 1 to 15 heat exchange cells, such as 2 to 10, 3 to 8, 4 to 7, or 5 to 7 heat exchange cells, each heat exchanger cell. heat exchange comprising a water plate 410 followed by a syngas 420 chilled current flow plate. In preferred embodiments for reforming approximately 2 SCMH of natural gas using off-gas PSA or final gas as fuel, the heat exchanger 166 comprises at least 4 heat exchange cells. In a preferred embodiment, heat exchanger 166 comprises 4 heat exchange cells, each heat exchange cell comprising a water plate 410 followed by a syngas 420 chilled current flow plate, and 4 end plates for a heat exchanger. total of 9 active boards. The number of heat exchange plates and cells can be modified according to production needs, heat exchange efficiency and other parameters. The water stream 108 may enter the cooled heat exchanger 165 at essentially the same temperature and pressure that left the heat exchanger 164 and may leave the exchanger 165 as reformer steam supply 172 at a temperature equal to the saturated steam temperature, such as between 175 and 225 ° C, between 180 and 210 ° C, between 185 and 205 ° C, between 190 and 205 ° C, between 195 and 200 ° C and at a pressure of between 1 mPaa and 10 mPaa, such as between 1 mPaa and 9 mPaa, between 1 mPaa and 7.5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1, 45 mPaa. The cooled stream of syngas 170 may enter the cooled heat exchanger 165 at a temperature of between 700 ° C and 1000 ° C, such as between 750 and 975 ° C, or between 800 and 950 ° C, between 825 and 925 ° C. or between 850 and 900 ° C and at a pressure of between 0.5 mPaa and 12 mPaa, such as between 1 mPaa and 10 mPaa, between 1 mPaa and 8 mPaa, between 1 mPaa and 6 mPaa , between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1, 6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa and can leave exchanger 165 at a temperature between 180 ° C and 210 ° C, such as between 185 and 205 ° C, 190 to 205 ° C or 195 to 200 ° C and at a pressure of between 0.5 mPaa and 12 mPaa, such as between 1 mPaa and 10 mPaa, between 1 mPaa and 8 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa, between 1.35 mPaa and 1.45 mPaa. Preferably, the pressure drop to the cooled stream of syngas 170 through exchanger 165 is less than 100 kPa, such as less than 7.5 kPa or less than 5 kPa. The water stream 108 is heated in the cooled heat exchanger 165 until it becomes steam at which point the steam leaves the cooled heat exchanger 165 through the steam outlet 167 as the reform steam supply 172. The reform steam supply 172 may be combined with gaseous hydrocarbon vapor 102 after steam 102 leaves syngas heat recovery heat exchanger 110 to form gaseous hydrocarbon vapor stream 174. Reform steam supply 172 and Gaseous hydrocarbon 102 may be joined in any suitable manner, such as by joining chains to form a single stream using a "Y" or "T" connector or by adding a stream within another stream. After combining the streams, gaseous hydrocarbon vapor stream 174 may be fed to the first preform stage or reformer module 150. In some embodiments, the reform steam supply 172 may include a back pressure regulator within. of its flow path prior to joining the gaseous hydrocarbon stream 102 to help provide stable boiling conditions during startup, capacity changes, and other transients, thus preventing liquid water oscillation into the reformer module or total lack steam flow to the reformer which could result in coke formation in the reformer and / or pre-reformer. In some embodiments, the gaseous hydrocarbon vapor stream may also include a check valve within its flow path prior to being attached to the reform steam supply 172.

After being cooled in the cooled heat exchanger 165, the syngas cooled current 170 may leave the heat exchanger 165 as the cooled syngas current 171 and pass through valve 185, which may be any suitable valve for controlling or tuning the supply of heat. cooled syngas 171 to syngas remixer 188. After proceeding through valve 185, the cooled syngas current 171 can be joined to syngas current 182 in syngas 188 remistifier. syngas current 182 proceeds from syngas divider 184 through fixed resistor 187, which may be a single orifice or any other high temperature flux control method. Generally, the syngas current 182 is too hot to employ a valve. Preferably, the syngas stream 182 is at a temperature of between 700 and 1000 ° C, such as between 750 and 975 ° C, or between 800 and 950 ° C, between 825 and 925 ° C or between 850 and 900 ° C and at a pressure of between 0.5 mPaa and 12 mPaa, such as between 1 mPaa and 10 mPaa, between 1 mPaa and 8 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa, between 1.1 bar and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1, 3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa. The syngas remixer 188 may be any apparatus suitable for joining two chains, such as by joining the chains to form a single chain using a "Y" or "T" connector or by adding one current within another current. Due to the temperature of the syngas stream 182 with respect to the temperature in the cooled syngas stream 171, a portion of the remixed syngas stream 189 and a part of the syngas stream 182 may be exposed to metal dusting conditions. Accordingly, a portion of the syngas stream 182 within about 5 tube diameters of remixer 188 and a portion of the remixed syngas stream 189 within about 5 tube diameters of remixer 188 are preferably constructed from alloys resistant to Metal dust forming and / or alloys having a metal dust resistant coating and / or are configured to perform easy repair, removal and replacement.

After being remixed, the remixed syngas stream 189 can proceed to an optional water and gas change reactor 186, where additional hydrogen is raised through the water and gas change reaction. When a water and gas change reactor is used, the temperature of the remixed syngas stream 189 is preferably between 250 and 350 ° C, such as between 275 and 325 ° C, between 280 and 310 ° C, between 290 and 305 ° C. C or 295 to 300 ° C.

After leaving the water and gas change reactor 186, the syngas stream 190 can proceed to the syngas heat recovery heat exchanger 110 where it can provide heat to the reagent feed streams, such as the hydrocarbon stream. 102, the flue gas fuel stream 112, the fuel feed stream 105, the air feed stream 107, the combustion air stream 114, and the water stream 108 (when the heat exchanger 109 It is part of syngas heat recovery heat exchanger 110). The syngas 190 stream leaving the high temperature shifting reactor may have a temperature of between 250 and 450 ° C, such as between 275 and 450 ° C, between 300 and 440 ° C, between 325 and 430 ° C, between 350 to 420 ° C, 375 to 410 ° C or 380 to 400 ° C and a pressure between 1 mPaa and 10 mPaa, between 1 mPaa and 8 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, 1 mPaa to 4 mPaa, 1 mPaa to 3 mPaa, 1 mPaa to 2 mPaa, 1 mPaa to 1.8 mPaa, 1.1 mPaa to 1.7 mPaa, 1.2 mPaa to 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa.

An example of an alternative embodiment for the steam reforming apparatus is illustrated in FIG. 5. As illustrated, the steam reforming apparatus 500 is substantially the same as the apparatus 100 described with respect to FIG. 1a and / or FIG. Except that in the steam reforming apparatus 500, the flue gas fuel stream 512 exceeds the syngas heat exchanger 510 and is combined with the flue gas stream 160 shortly before the flue gas preheater enters. 175 to form the fuel-rich flue gas stream 162. The flue gas fuel stream 512 may be combined with the flue gas stream 160 in any suitable manner such as by joining the streams to form a single stream using conector "or" T "connector or by adding a current within another current. Since flue gas fuel stream 512 exceeds the heat exchanger syngas 510 heat, the syngas 510 heat recovery heat exchanger is configured slightly differently, having only 4 reagent feed streams (fuel feed stream 105, air feed stream 107, combustion 114 and gaseous hydrocarbon feed stream 102), optionally water feed stream 108 (when heat exchanger 109 is included in heat exchanger 510) and syngas stream 190 flowing therethrough.

An illustrative embodiment of the plates that may form the syngas 510 heat recovery heat exchanger is illustrated in FIGS. 6a-c. Referring to Figures 6a-c, in some embodiments the syngas 510 heat recovery heat exchanger may comprise a PCHE which is constructed from a series of plates which may be combined in a stack and diffused together. to form the heat exchange between the hot and cold inlet currents. In general, the flow paths for each of the streams may be formed on the plates by engraving, grinding or other suitable process and may be configured to provide the desired heat exchange, while limiting the pressure drop to one or more streams through the heat exchanger. heat exchanger. Preferably, the streams entering and leaving the exchanger 510 are maintained under temperature, pressure and composition conditions that prevent or reduce the conditions of metal dust formation within the heat exchanger. In some cases, currents entering and leaving the heat exchanger 510 are below the metal dusting temperatures. In general, the syngas heat recovery heat exchanger 510 is essentially the same as the syngas heat recovery heat exchanger 110 shown in Figures 1 and 2a-c, except that the recovery heat exchanger 510 does not heat the combustion gas fuel stream 512. According to this minor exception, the overall construction of the syngas 510 heat recovery heat exchanger, the appropriate plate and channel dimensions, thicknesses and Construction materials for each of the plates and process conditions are substantially the same as described with respect to Figures 2a-c.

Referring to Figures 6a-c, in some embodiments, the syngas heat recovery and heat exchanger 510 may comprise one or more joining plates 610, one or more reagent feed plates 625, and one or more syngas plates 650 In the embodiment illustrated in Figure 6a-c, the plates, when properly stacked and formed in a heat exchanger, will form a syngas heat recovery heat exchanger 510 including heat exchanger 109 (see Figure 5). Figure 6a illustrates a junction plate 610 having a syngas flow path 611 comprising independent flow channels 612 connecting the syngas inputs 613 with the syngas outputs 614. Although figure 6a illustrates the syngas flow path 611 as a multipath flow path, the flow path 611 may also comprise a forward direct flow, simultaneous flow, cross flow or single pass flow path comprising one or multiple independent channels 612. In some embodiments, the path syngas 611 comprises more than one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 100 passes, from 5 to 75 passes, from 10 to 60 passes, from 15 to 50 passes or from 20 passes. to 40 passes. Preferably, the syngas flow path 611 comprises a multipass flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages, or 30 or more passages where The passages are cross-flow during heat exchange, but syngas flows in a generally cross-flow direction or counter-flow direction with respect to flows on the reagent feed plate 260. The union plate 610 also includes the penetrations of 615, combustion air stream penetration 616, fuel stream penetration 617, fuel and air mixture penetration 661, gaseous hydrocarbon stream penetrations 618, water stream penetrations 619 and syngas 620 current penetrations. The union plate 610 ensures that all 625 reagent feed plates have hot current plates on both sides of the and a junction plate 610 or syngas plate 650 and helps to balance heat loads and heat flow through all the stacks. Junction plate 610 may have more than one flow channel 612.

Referring to Figure 6b, the syngas plate 650 includes syngas inputs 651, syngas outputs 652, and syngas flow path 653. The syngas flow path 653 may comprise one or more syngas independent flow channels 654. Although of a specific number of syngas independent flow channels 654 being illustrated, it should be understood that syngas flow path 653 may comprise any desired number of independent flow channels configured appropriately according to the individual needs of the system.

Although figure 6b illustrates the flow path of syngas 653 having a specific number of passages, in some embodiments the syngas flow path 653 may comprise more than one pass, each passage comprising a single flow reversal such as 2 100 passes, 5 of 75 passes, 10 to 60 passes, 15 to 50 passes, or 20 to 40 passes. Preferably, the syngas flow path 653 comprises a multipass flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages, or 30 or more passages where The passages are cross-flow during the heat exchange, but syngas flows in a generally cross-flow or counter-flow direction relative to the flows on the 525 reagent feed plate. The syngas 650 plate also has airflow penetrations 655 , combustion air stream penetration 656, fuel stream penetration 657, fuel and air mixture penetration 663, gaseous hydrocarbon stream penetrations 658, water stream penetrations 659 and syngas stream penetrations 660.

Referring to Figure 6c, the reagent feed plate 625 has airflow penetrations 621, combustion airflow penetration 622, fuel currentflow penetration 623, fuel and air mixture penetration 662, airflow penetrations gaseous hydrocarbon 624, water stream penetrations 626 and syngas 646 stream penetrations. Reagent feed plate 625 includes airflow path 627 with air inlets 628 and air outlets 629, airflow path 630 with combustion air inlets 631, fuel flow path 632 with fuel inlets 633 and fuel and air mixture outlets 634 and gaseous hydrocarbon flow path 635 with gaseous hydrocarbon inlets 636 and gaseous hydrocarbon outlets 637. Each of the flow paths 627, 630, 632 and 635 may comprise one or multiple independent flow channels 638, 639, 640 and 641 and adjacent projections. They can be sized to provide safe pressure containment and a cheap combination of heat transfer capability and pressure drop. Although the specific number of independent flow channels 638, 639, 640 and 641 is illustrated in Figure 6, it should be understood that each of the flow paths 627, 630, 632 and 635 may comprise any suitable number of flow channels. independently configured to suit individual system needs.

Although Figure 6c illustrates each of the flow paths 627, 630, 632 and 635 as being cross flow and / or single pass, in some embodiments one or more of the flow paths 627, 630, 632 and 635 may comprise multiple passages, such as from 2 to 20 passages, from 2 to 10 passages or from 2 to 5 passages. Preferably, flow paths 627, 630, 632 and 635 are cross flow and / or single pass flow path. In Figure 6c, the combustion air flow path 630 is configured to provide the combustion air stream mixture 114 of Figure 5 with the fuel feed stream 105 within the exchanger 510 by directing the flowing air. through the flow path 630 and the fuel flowing in the flow path 632 for the same penetration, fuel mixture and air penetration 662. When configured in this way, there is no separate union of these currents downstream of the recovery heat exchanger. 510 heat exchanger as shown in Figure 5. The reagent feed plate 625 also includes a water flow path 642 that connects water flows 643 and water flows 644 as shown in bottom left of reagent feed plate 625 in figure 6c. Water stream flow path 642 may comprise one or multiple independent flow channels 645. That portion of reagent feed plate 625, when formed in a heat exchanger, corresponds to the water flow streams for heat exchanger 109 flow channels 645 may be sized to provide adequate water supply at the desired pressure and temperature for the rest of the reformer system 500. Although an independent flow channel 645 is illustrated in figure 6c, It will be appreciated that flow path 642 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system.

Although Fig. 6c illustrates flow path 642 configured as a multipath or multipath counter flow path, it can also be cross flow, simultaneous flow and / or single pass. In some embodiments, the flow path 642 may comprise more than one pass, each pass comprising a single reversal in the flow direction, such as from 2 to 100 passes, from 5 to 75 passes, from 10 to 60 passes, from 15 to 50 passes or 20 to 40 passes. Preferably, the water stream flow path 642 comprises a multi-pass flow path having 5 or more passages, 10 or more passages, 20 or more passages, 25 or more passages or 30 or more passages where the passages are in cross flow during the heat exchange, but water flows in a generally cross flow or counter flow direction relative to the syngas flow in the syngas 650 plate.

When stacked and joined by diffusion or otherwise to form a heat exchanger, the various joining plates 610, reagent feed plates 625 and syngas plates 650 are preferably aligned such that each of the various air stream penetrations. 615, 621 and 655, combustion air stream penetrations 616, 622 and 656, fuel stream penetrations 617, 623 and 657, fuel and air mixture penetrations 661, 662 and 663, gaseous hydrocarbon stream penetrations 618 , 624 and 658, water stream penetrations 619, 626 and 659 and syngas 620, 627 and 660 current penetrations form the flow path or access chambers for connecting each of the various streams to the appropriate inlets and outlets for the various flow paths. The plates may be stacked in order as described with respect to Figure 2 and may comprise the same number of cells and configuration as described with respect to Figure 2. In addition to the alignment of the various penetrations, the stacking of the plates preferably places independent channels 638. 639, 640 and 641 creating flow paths 627, 630, 632 and 635 in proximity to independent channels 612 and 654 creating flow paths 611 and 653 to facilitate heat transfer between the relevant currents through the respective wall walls. independent channels.

An example of another alternative embodiment for the steam reforming apparatus is illustrated in FIG. 7. As illustrated, the steam reforming apparatus 700 is substantially the same as the apparatus 100 described with respect to FIG. 1a and / or FIG. except that in the steam reforming apparatus 700, the flue gas stream 160 is not preheated prior to entering the heat exchanger 164. According to Figure 1a, the fuel supply stream 104 is not split, there is no flue gas fuel stream 114 and flue gas preheater 175 has been removed as well. As a result, the syngas 710 heat recovery heat exchanger can be configured as discussed above with respect to figures 6a-c. The configuration in figure 7 lends itself to situations in which the reformer is operated at elevated temperatures relative to the system of figure 1a. In such situations, the syngas stream 180 and the flue gas stream 160 leave the reforming stages at temperatures approaching 1000 ° C. At this higher temperature, additional steam raised with the aid of combustion chamber 175 of FIG. 1a or 5 is not required as reforming at a higher temperature gives a higher methane conversion for a given vapor to carbon ratio. and the additional heat recovered from the syngas stream 180 and the flue gas stream 160 is sufficient to raise the steam required for reforming at elevated temperatures.

Referring to Figures 1a, 5 and 7, each of the reforming apparatus 100, 500 and 700 includes a reforming module 150. The reforming module 150 reforms the gaseous hydrocarbon vapor stream 174 to form the syngas stream 180 and the stream. 160. During the reforming process, the reforming fuel vapor 124 is combined in the presence of reforming airstream 126 to provide additional heat to the reforming process. An example of one embodiment of a reformer module 150 is illustrated in Figure 8. As illustrated in Figure 8, in some embodiments the reformer module 150 may comprise a pre-reformer 800 and a reformer 820. Pre-reformer 800 may comprise multiple stages. 801, 802, and 803 heat exchange between gaseous hydrocarbon vapor stream 174 and flue gas stream 160 on heat exchangers 804, 805 and 806 followed by partial catalytic reforming of gaseous hydrocarbon vapor stream 174 on catalytic reforming chambers or beds 807, 808 and 809. Although the embodiment in Figure 8 illustrates three 801-803 pre-reform stages, the number of pre-reform stages may vary from 1 to 10 depending on system requirements. Preferably, coke and metal dust forming conditions are avoided by all pre-reforming stages. In operation, pre-reformer 800 includes multiple interactions or stages of heating the gaseous hydrocarbon vapor stream 174 by recovering heat from the flue gas stream 160 followed by a partial catalytic reforming of the heated gaseous hydrocarbon vapor stream .

In some embodiments, pre-reformer 800 comprises a PCR that is constructed from a series of plates as illustrated in figures 9a-e that have been stacked and diffused or otherwise joined to form a PCR. Such a PCR may be configured similar to a SHP, with catalytic chambers or beds intermittently supplied within the flow path of the gaseous hydrocarbon vapor stream 174 so that the stream may be heated alternately by the flue gas stream 160 and then partially reformed causally. The PCR can be constructed from a series of plates that can be combined into a stack and diffused together or otherwise to provide heat exchange between hot and cold currents by placing the channels that create the flow paths into each other. proximity to each other and to provide catalytic reforming of the gaseous hydrocarbon vapor stream 174. The stacking may include the stacking of end plates, joining plates and specific configurations of gaseous hydrocarbon vapor and flue gas plates accordingly. with the desired heat transfer. In general, the flow paths for each of the streams may be formed as channels in the plates by engraving, grinding or other suitable process and may be configured to provide the desired heat exchange, while limiting the pressure drop to one or more of the two. currents through PCR. The channels in each plate can be configured for single-pass or multi-pass heat transfer between currents, and can be configured to operate in simultaneous flow, cross flow or reverse flow. In some embodiments, plates for one stream may be configured for multiple passes, while plates for another stream are configured for single passes. Preferably, streams entering and leaving the PCR are maintained at the same temperature, pressure and composition that prevent or reduce the metal dusting conditions within the PCR. The embodiment illustrated in Figures 9a-e comprises three pre-reform stages.

Referring to Figures 9a-e, in some embodiments, the PCR may comprise one or more joining plates 910, one or more flue gas plates 920, one or more gaseous hydrocarbon vapor plates 950, one or more upper end 970 and one or more lower end plates 980. For such non-penetrating plates and streams through which flow paths and flow channels are accessed, the heads may be fixed, as welded, through ends. individual channel channels at the end of the stacked plates to facilitate distribution and / or collection of current flowing through the relevant channels. In some embodiments, such a head may comprise a portion of the tube or tubing that has been opened on one side to provide flow of individual channels directly within the tube or tubing. Figures 9a-e each include insulating cutouts A and Figure 9c also include insulating penetrations B. Insulating cutouts A cover the full height of the PCR stack when the plates are stacked and formed in a PCR and serve to control heat flow and prevent undesirable heat flow from the hot portions of the plate currents to cool the portions of the same currents in the same plate by driving along the plates by providing a reduced heat transfer region between the currents. . Insulation penetrations 9b serve the same purpose, but are present only in gaseous hydrocarbon vapor plates 950 and do not cover the height of the entire stack. Figure 9a illustrates a junction plate 910 having a flue gas flow path 911 comprising multiple independent flow channels 912 connecting flue gas inlets 913 with flue gas outlets 914. Junction plate 910 also includes reformatting or bed chamber penetrations 915, 916 and 917 and gaseous hydrocarbon stream penetration 918. Junction plate 910 helps serve to balance heat loads and heat flow throughout the stack when formed in a heat exchanger .

Referring to Figure 9b, the flue gas plate 920 includes the chamber or retirement bed penetrations 921, 922 and 923 and the gaseous hydrocarbon stream penetration 924. The flue gas plate 920 also includes the flow path. 927 with flue gas inlets 926 and flue gas outlets 925. Flow path 927 may comprise one or multiple independent flow channels 928. Despite a specific number of independent flow channels 928, shown in Figure 9b, it should be understood that flow path 927 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system. Additionally, while Figure 9b illustrates flow path 927 as cross flow or single pass, in some embodiments flow path 927 may comprise multiple passages, such as from 2 to 20 passages, from 2 to 10 passages, or 2 to 5 passes. Preferably, flow path 925 is a single flow or cross flow flow path.

Referring to Figure 9c, the gaseous hydrocarbon vapor plate 950 includes chamber or retirement bed penetrations 951,952 and 953 and gaseous hydrocarbon stream penetration 954. Gaseous hydrocarbon vapor plate 950 includes hydrocarbon vapor flow path. 955 with gaseous hydrocarbon vapor inlets 956 and reformer current outputs 957. Flow path 955 may comprise one or multiple independent flow channels 958. Although a specific number of independent flow channels 958 is illustrated in Figure 9c It should be understood that flow path 955 may comprise any suitable number of independent flow channels configured appropriately to the individual needs of the system. Additionally, while Figure 9c illustrates flow path 955 as a combination of multipass cross flow and single pass cross flow, in some embodiments flow path 955 may comprise multiple flow passages, such as from 2 to 2. In 20 passages, 2 to 10 passages or 2 to 5 passages and in other embodiments, flow path 955 may comprise single pass cross flow, simultaneous flow or reverse flow. Preferably, flow path 955 is a combination of multiple cross flow and single pass cross flow during heat exchange, while flowing in a generally counter flow or cross flow direction with respect to the flue gas stream 160. In some embodiments, flow path 955 comprises multiple cross flow passages between inlet 956 and the first chamber or reformatting bed penetration 951, while flowing in a generally counter-flow direction and single pass cross flow between the first and second combustion chambers and second and third combustion chambers, while still flowing in a direction generally contrary to flow.

In some embodiments, Figure 9c also includes gaseous hydrocarbon vapor channels 960 and reformer current channels 961. Gaseous hydrocarbon vapor channel 960 may serve to feed gaseous hydrocarbon vapor stream 174 into pre-flow. 800 and the gaseous hydrocarbon stream penetrations 954 and can be supplied through a head that can be welded or connected over the ends of the individual channels through the stack of plates that create the PCR. The gaseous hydrocarbon vapor penetrations 954, together with the gaseous hydrocarbon vapor stream penetrations in the other plates may form a chamber which may be an empty chamber or may optionally contain catalyst to further reform the hydrocarbon vapor stream. In some embodiments, such as embodiments where channels 960 are not included, the chamber formed from the gaseous hydrocarbon vapor stream penetrations may serve as input to the gaseous hydrocarbon vapor stream 174. on the pre-reformer 800 by powering the current through a port attached to an end plate providing access to the chamber. Similarly, the reformer current channels 961 may serve to collect the reformer current 811 by flowing into the individual preformer 800 plates as the current 174 completes its preform in the chamber formed by the chamber or bed bed penetrations. 917, 923 and 953 and power endplates for the reformer 820. Channels 961 can feed current into a printhead that can be welded or otherwise connected to the pre-reformer through the ends of the individual channels through from the stack of the plates that create the PCR. Channels 960 and 961 can be configured and sized the same or different from channels 958 and there may be the same number of channels 960 and 961 or a different number compared to channels 958. Generally, channels 960 and 961 may independently have the sizes described in table 1.

Referring to Figure 9d, the upper end plate 970 may be a blank plate or a plate without any flow path circuitry and may be insulated to improve heat transfer and limit heat loss. In some embodiments, the upper end plate 970 may include inputs and outputs or ports for input and output of various currents. In some embodiments, multiple upper endplates may be used at each end. In some embodiments, a single upper end plate 970 is used. In other embodiments, multiple upper endplates may be used to provide sufficient thickness for the heads or doors. Similarly, with reference to Fig. 9e, the lower end plate 980 may be a blank plate or plates without any flow path circuitry and may be insulated to improve heat transfer and limit heat loss. In some embodiments, the lower end plate 980 may include inlets and outlets or ports for multiple current inlets and outlets, such as penetration 984 in addition to access to the catalytic chambers through the access ports 981, 982, and 983 formed when individual plates are stacked In some embodiments, lower end plate 980 may not include penetration 984. In some embodiments, multiple lower end plates may be used. In some embodiments, a single lower end plate 980 is used. In other embodiments, multiple endplates may be used to provide sufficient thickness for the heads or doors. In some embodiments, the endplates may provide a wall against the boundary plate adjacent to the upper endplate, serving as caps for penetrations and supporting connection of relevant currents with PCR 900, such as through ports or heads. Accordingly, the endplates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors or heads.

When stacked and diffused or otherwise joined to form a PCR, the various boundary plates 910, flue gas plates 920 and gaseous hydrocarbon vapor plates 950 are preferably aligned such that each of the various chamber penetrations or retirement bed 915, 921 and 951, and 916, 922 and 952 and 917, 923 and 953 are aligned to form retirement chambers or retirement beds, such as retirement chambers or beds 807, 808 and 809. Chambers or reforming bed may be loaded with structured or unstructured catalyst and the reforming reaction may be catalyzed using any suitable catalyst. Additionally, the various plates are preferably aligned such that the gaseous hydrocarbon vapor penetrations 918, 924, 954 and 984 form a path or flow access chamber for the gaseous hydrocarbon vapor stream.

In addition to the alignment of the chamber or reforming bed penetrations, the stacking of the plates preferably places flow paths 911, 925 and 955 in close proximity to each other to facilitate heat transfer between the relevant currents through the independent channel walls. 912, 928, and 958. In some embodiments, such heat transfer is depicted in Figure 8 as heat exchangers 804, 805, and 806.

In some embodiments, the plates may be stacked and diffused or otherwise joined in any suitable order to form a PCR. In some embodiments, the plates may be stacked in the following order: at least one upper end plate 970, a boundary plate 910, multiple preform cells, each preform cell comprising a flue gas plate 920 and a gaseous hydrocarbon plate 950, followed by another flue gas plate 920, another limit plate 910, and a lower end plate 980. Accordingly, the order of the printed circuit reactor plates in a given stack can have the following standard for the active plates (limit plate 910 = B, flue gas plate 920 = F, gaseous hydrocarbon plate 950 = G): BFGFGF G ... FGFGF B. A perspective view of a pressure plate flue gas 920 and a gaseous hydrocarbon plate 950, i.e. a preform cell, is illustrated in figure 10. End plates may be blank plates without any flow path circuitry and may be isolated stop me improve heat transfer and limit heat loss. End plates can serve as caps for flow access chambers and paths formed by the alignment of penetrations and support connection of relevant currents to the PCR, such as through ports or heads in fluid connection with chambers and flow paths. flow. Accordingly, the end plates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors or heads. In some embodiments, a single end plate is used for each end of the PCR where the end plate is thicker than the other plates. In other embodiments, multiple endplates may be used at each end to provide sufficient thickness to support or provide the heads or doors.

In a specific embodiment for reforming 2 natural gas SCMHs using PSA off-gas as fuel, the PCR comprises 3 upper endplates, followed by a boundary plate 910 followed by 11 reforming cells followed by a 920, followed by a boundary plate 910 and 3 lower end plates. This configuration results in a stacked 800 pre-reformer that is 49.6 mm. in height when using plates having a thickness of 1.60 mm. Preferably, the PCR that creates preformer 800 is constructed from materials suitable to withstand the pressures and temperatures to which preformer 800 is exposed. In some embodiments, the PCR and therefore pre-reformer 800 may be constructed from alloy 800H or alloy 617.

The individual plates that create the PCR may independently have the thicknesses described in Table 1. In some embodiments, the plates may each be 1.6 mm. of thickness. Additionally, each of the independent flow channels 912, 928 and 958 may independently comprise a generally semicircular cross section and may independently have the dimensions described in Table 1. In some embodiments, each of the independent flow channels 912, 928 and 958 may have a semicircular cross section and may have a width of about 1.99 mm., a depth of about 1.1 mm. and about 0.5 mm. of overhangs.

In some embodiments, the PCR may operate as follows: the gaseous hydrocarbon vapor stream 174 may enter the first stage of reform 801 through the gaseous hydrocarbon vapor inlet 956 and the flow path or access chamber formed at from aligning the gaseous hydrocarbon vapor penetrations 918, 924, 954 and 984 and the end plates 970 and 980 and entering the gaseous hydrocarbon vapor flow path 955 into the gaseous hydrocarbon vapor plates 950. The hydrocarbon vapor gas flows through the gaseous hydrocarbon vapor inlet 956 into the independent flow channels 958 in the gaseous hydrocarbon vapor plates 950 where the current is heated by the flue gas that entered the PCR in the flue gas plates 920 and boundary 910 and is flowing in independent flow channels 928 and 912 of flow paths 925 and 911 respectively. In the embodiment in FIGS. 9a-e, during the first stage of heat exchange, independent flow channels 958 form a flow path 955 which has multiple passages and is cross-flow during heat exchange with respect to the flue gas it is flowing on single pass flow paths 927 and 911.

After the first heating stage, gaseous hydrocarbon vapor flowing in the channels 958 is directed to the reforming chamber or bed 807 formed from the alignment of the reforming penetrations 915, 921, and 951 and the end plates and is partially reformed into the vane. -litically. This partially reformed stream then enters the second preform stage 802 where it is heated by the flue gas stream 160. In this second heating stage, the independent flow channels 958 form a flow path 955 which is a flow path of single flow flowing in cross flow with respect to the flue gas flowing in the single flow flow paths 927 and 911.

After the second heating stage, the partially reformed current flowing in channels 958 is directed into the reforming chamber or bed 808 formed from the alignment of reforming penetrations 916, 922 and 952 and the end plates and is partially catalytically reformed. . The resulting partially reformed stream then enters the third preform stage 802 where it is heated by the flue gas stream 160. In this third heating stage, independent flow channels 958 form a flow path 955 which is a flow path single pass flow flowing in relation to the flue gas flowing in the single pass flow paths 925 and 911.

After the third heating stage, the partially reformed current flowing in channels 958 is directed into the reforming chamber or bed 809 formed from the alignment of reforming penetrations 917, 923 and 953 and the end plates and is partially catalytically reformed. . The stream leaving chamber or retirement bed 809 leaves pre-reformer 800 as reformer chain 811 and proceeds to the first reform stage on reformer 820. Flue gas stream 160 leaves pre-reformer 800 and is optionally reheated in a combustion chamber 175 before providing additional heat to the water stream 108 in the heat exchanger 164 before leaving the reformer system 100.

In some embodiments, the gaseous hydrocarbon vapor stream 174 enters pre-reformer 800 at a temperature just below or above the saturated steam temperature such as between 200 ° C and 270 ° C, between 210 ° C and 260 ° C, between 215 ° C and 250 ° C, between 220 ° C and 240 ° C, or between 225 ° C and 240 ° C and at a pressure of between 10 mPaa and 100 mPaa, such as between 1 mPaa and 9 mPaa, between 1 mPaa and 7.5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1.8 mPaa , between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa and may leave the pre- reformer 800 as a reformer current 811 at a temperature of between 500 ° C and 700 ° C, such as between 510 ° C and 675 ° C, between 520 ° C and 650 ° C, between 530 ° C and 625 ° C, 550 ° C to 600 ° C, or between 560 ° C and 590 ° C and at a pressure of between 1 mPaa and 10 mPaa, such as between 1 mPaa and 9 mPaa, between 1 mPa a and 7,5 mPaa, between 1 mPaa and 6 mPaa, between 1 mPaa and 5 mPaa, between 1 mPaa and 4 mPaa, between 1 mPaa and 3 mPaa, between 1 mPaa and 2 mPaa, between 1 mPaa and 1,8 mPaa, between 1.1 mPaa and 1.7 mPaa, between 1.2 mPaa and 1.6 mPaa, between 1.3 mPaa and 1.5 mPaa or between 1.35 mPaa and 1.45 mPaa. Flue gas stream 160 may enter pre-reformer 800 at a temperature of between 700 ° C and 1050 ° C, such as between 750 ° C and 1000 ° C, between 800 ° C and 950 ° C, between 825 ° C 925 ° C, between 850 ° C and 900 ° C, and at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than 7.5 kPa, or less than 5 kPa, and you can leave pre-reformer 800 at a temperature between 500 ° C and 650 ° C, such as between 510 ° C at 625 ° C, between 520 ° C and 600 ° C, between 530 ° C and 575 ° C and at a pressure of less than 100 kPa, such as less than 75 kPa, less than 50 kPa, less than 40 kPa, less than 30 kPa, less than 20 kPa, less than 15 kPa, less than 10 kPa, less than 75 bar or less than 5 kPa.

Referring to Figure 8, after leaving Pre-Reformer 800, the Reformer 811 chain enters Reformer 820. As illustrated in Figure 8, Reformer 820 comprises multiple reforming stages such as 821, 822, 823, 824, and 825. and stages represented by break 880 which should represent any suitable number of stages configured essentially equal to stages 821-825 as described below, each stage including the heat exchange from the reformer air stream 126 into the reformer current 811 in the heat exchangers. 831, 832, 833, 834 and 835 followed by the catalytic reformer of the reformer stream 811 in the reformers 841, 842, 843, 844 and 845 and the reheating of the reformer air stream 126 by catalytic combustion of a portion of the fuel stream 124 in combustion chambers 851, 852, 853, and 855. The reformer fuel stream 124 can be supplied in parallel to the individual stages through s of a fuel distribution network comprising the reforming fuel stream 124 and the reforming stage fuel streams 861, 862, 863 and 865. Although figure 8 illustrates five complete stages 821, 822, 823, 824 and 825, it should be understood that any suitable number of retirement stages may be used, such as from 1 to 40 stages of reform, such as from 2 to 35 stages, from 3 to 30 stages, from 5 to 25 stages, from 8 to 20 stages or from 10 to 15 stages of reform as represented by the break in 880. It should also be noted that later stages of reform may not require reheating of the reformer airflow 126 to provide adequate heat for catalytic reforming and thus one or more of the last stages may not include the reheat step of the reformer air stream 126, may not include the combustion chambers or may not have the catalyst in their combustion chambers and / or may not include a reform stage fuel stream. In some embodiments, the last reform stage does not include reheating of the reformer air stream 126. For example, although reform stage 824 illustrates a combustion chamber 875, it does not include a fuel supply and thus combustion chamber 875 may not include catalyst and additional combustion may not occur. Alternatively, the combustion chamber 875 may include the catalyst and may contain any remaining combustible components in the reformer air stream 126. Preferably, the conditions of metal dust and coke formation are avoided by all stages of reforming.

In some embodiments, reformer 820 comprises a PCR. The PCR may be configured similarly to a printed circuit heat exchanger ("PCHE"), with the reforming catalyst chambers or beds intermittently supplied within the reformer stream flow path 811 and the reforming catalyst chambers. intermittently supplied within the flow paths to the reformer air stream 126 and the reformer fuel stream 124 so that the reformer stream 811 can be heated alternately by the reformer air stream 126 and then partially reformatted. lithically while the reformer air stream 126 alternately heats the reformer stream 811 and is reheated by combustion of a portion of the reformer fuel stream 124. The PCR can be constructed from a series of plates which can be combined into one diffused or otherwise joined to provide heat exchange between hot and cold currents by channels that create flow paths in close proximity to each other and to provide catalytic reforming of reformer stream 811 and catalytic combustion of a portion of reforming fuel stream 124 in the presence of reforming airstream 126. Stacking may include stacking of end plates, boundary plates, and specific configurations of reformer current plates, reformer air plates, and reformer fuel plates.

In general, the flow paths for each stream may be formed as channels in the plates by engraving, grinding or other suitable process and may be configured to provide the desired heat exchange while controlling pressure drops for one or more of the currents through PCR. The channels in the reforming plates and current and the reforming airflow plates can be configured for single or multi-pass heat transfer between currents, and can be configured to operate in simultaneous flow, cross flow or counter flow. . In some embodiments, the plates for one of the reform currents or reform air currents may be configured for single passages. Preferably, streams entering and leaving the PCR are maintained at the same temperature, pressure and composition conditions to avoid or reduce the conditions of metal powder and coke formation within the PCR.

An example of the plates that create one embodiment of such a PCR can be found in figures 11a-f. The embodiments illustrated in figures 11a-f comprise 14 reforming stages, but it should be understood that any suitable number of stages may be used with suitable modification to the various illustrated plates. Referring to FIGS. 11f, the PCR may comprise one or more boundary plates 1101, one or more reformer plates 1121, one or more reformer air plates 1141, one or more reformer fuel plates 1161, one or more upper end plates 1180 and one or more lower end plates 1190.

Referring to Figure 11a, the boundary plate 1101 includes the reformer current input chamber penetration 1102 and the reformer current output chamber penetration 1103, which may also be the last chamber or reformatting bed penetration, and a flow path 1104 comprising multiple independent flow channels 1105. In general, boundary plate 1101 will have fewer independent flow channels 1105 than the number of independent flow channels in reformer plate 1121. In some embodiments, the plate 1102 has half the number of independent flow channels as the reformer plate 1121. As illustrated in the expanded view of the limit plate 1101 in Figure 11aa, an example of a single reform stage 1110 of the 14 stages included in the limit plate 1101 includes a chamber or retirement bed penetration 1112, a combustion chamber penetration 1114 and a fuel supply penetration 1113. Limit plate 1101 helps serve to balance heat loads and heat flow throughout the stack when formed in a heat exchanger.

Although figure 11aa illustrates the reformer chamber penetration 1112 on the right side of the limit plate 1101, it should be understood that the reformer chamber penetrations for the alternate side reforming stages along the limit plate 1101 with penetrations 1113 from the first entry penetrations or penetrations 1102 to the last penetrations or exit penetrations 1103 and may be initiated on either side of the limit plate 1101. Accordingly, the stages immediately before and after stage 1110 will have the chamber penetrations or reforming bed 1112 on the left side of the limit plate 1101 and fuel supply penetrations 1113 on the right side of the limit plate 1101. In some embodiments, stages may be configured differently as appropriate for the intended use and The process and apparatus embodiments described herein should not be construed as limited to alternating the various penetrations. For example, where the heat exchange includes one or more passages, the configuration may change to accommodate these passages.

In operation, a portion of reformer stream 811 flows through independent channels 1105 where it recovers heat from the heated reformer air stream 126 by flowing into independent channels 1145 illustrated in FIGS. 11c and 11cc and then proceeds to penetration of reformer chamber 1112. The reformer chamber penetrations 1112 (including penetrations 1102 and 1103) match the corresponding reformer chamber penetrations 1132 (including penetrations 1122 and 1123), 1152, 1172, and 1192 in the plates in figures 11 bd and f, respectively. to form the reformer chambers, such as the reformer chambers 841, 842, 843, 844 and 845 illustrated in FIG. 8, where the reformer chain 811 is partially catalytically reformed. In some embodiments, the chamber formed by the inlet penetrations 1102 together with the corresponding penetrations in the other plates may be aligned to form a blank or empty chamber that does not include the catalyst and does not reform the reformer stream 811. After being partially reformed reformer chain 811 leaves the reformer chamber and recovers heat in the next reform stage until it leaves the last reform stage through the reformer current output penetrations 1103, at which point the reformed current is combined with the current section leaving the last reform stage on the reformer plate 1121 to form the syngas chain 180. Figure 11b illustrates the reformer plate 1121 having reformer current input penetration 11 and current output chamber penetration. 1123, which may also be the last chamber penetration or retirement bed, and a and flow 1124 comprising multiple independent channels 1125. As illustrated in the expanded view of the reformer plate 1121 in Figure 11bb, an example of a single reforming stage 1130 of the 14 stages included in the reformer plate 1121 includes a chamber or bed penetration. 1132, a combustion chamber penetration 1134 and a fuel supply penetration 1133. Although figure 11 bb illustrates the penetration of reformer chamber 1132 on the right side of the reformer plate 1121, it should be understood that the penetrations chamber chambers for alternating side reforming stages along reformer plate 1121 with fuel supply penetrations 1133 from inlet penetrations 1122 to outlet penetrations 1123 and can be initiated on either side of the reformer plate 1121. Accordingly, the stages immediately before and after stage 1130 will have camera penetrations. chamber and bed 1132 on the left side of the reformer plate 1121 and fuel supply penetrations 1133 on the right side of the reformer plate 1121. In some embodiments, stages may be configured differently as appropriate for the intended use and modalities. The method and apparatus described herein should not be considered limited by the alternation of the various penetrations. For example, where the heat exchange includes one or more passages, the configuration may change to accommodate these passages.

In operation, a portion of reformer stream 811 flows through independent channels 1125 where it recovers heat from the heated reformer air stream 126 flowing in independent channels 1145 illustrated in figures 11c and 11cc and then proceeds to penetration of reformer chamber 1132. The reformer chamber penetrations 1132 (including penetrations 1122 and 1123) match the corresponding reformer chamber penetrations 1112 (including penetrations 1102 and 1103), 1152, 1172 and 1192 in the plates in figures 11a, cd and f for. forming the reformer chambers, such as the reformer chambers 841,842, 843, 844 and 845 illustrated in FIG. 8, where the reformer chain 811 is partially catalytically reformed. In some embodiments, the chamber formed by the inlet penetrations 1122 together with the corresponding penetrations in the other plates may be aligned to form a blank or empty chamber which does not include the catalyst and does not reform the reformer stream 811. After being partially reformed , the reformer current 811 leaves the reformer chamber and recovers heat in the next reform stage until it leaves the last reform stage and enters the reformer current outlet penetrations 1123, at which point the reformed current is combined with the reformed chain leaving the last reform stage on the reformer plate 1101 to form the syngas 180 chain.

In some embodiments, figures 11a-b also include the reformer current input channels 1106 and 1126 and the reformer current output channels 1107 and 1127. The reformer current input channels 1106 and 1126 may be fed to reformer current 811 within reformer 820 and inlet penetrations 1102 and 1122 and may be supplied through a head that can be welded or connected through the ends of the individual channels through the plate stack that creates the PCR. The inlet penetrations 1102 and 1122, together with the corresponding penetrations in the other plates may form a chamber which may be an empty chamber or which may optionally contain the catalyst to further reform the reformer stream into the reformer 820. In some embodiments, Like embodiments where channels 1106 and 1126 are not included, the chamber formed from the inlet penetrations may serve as input to the reformer current 811 within pre-reformer 800 by feeding the current through a port attached to a end plate that provides access to the camera. Similarly, reformer current output channels 1107 and 1127 may serve to collect the syngas 180 current flowing in the individual reformer plates 820 as current 811 completes its reform in the chamber formed by chamber or bed penetrations. 1103 and 1123 and the corresponding penetrations into the other plates and end plates. Channels 1107 and 1127 may feed current 180 into a weldable head or otherwise connected to the pre-reformer through the ends of the individual channels through the plate stack that creates the PCR. Channels 1106, 1107, 1126, and 1127 can be configured and sized the same or differently than channels 1105 and 1125 and there may be an equal or different number of channels 1106, 1107, 1126, and 1127 compared to channels 1105 and 1125. Generally the Channels 1106, 1107, 1126, and 1127 may independently have the sizes described in Table 1. Figure 11c illustrates a reformer air plate 1141 having reformer air inlets 1142 and reformer air outlets 1143 and a flow path 1144. comprising multiple independent annals 1145. As illustrated in the expanded view of the reformer air plate 1141 in Figure 11cc, an example of a single stage reforming 1150 of the 14 stages included in the reformer air plate 1141 includes a chamber penetration or reformer bed 1152, a combustion chamber penetration 1154 and a fuel supply penetration 1153. Although figure 11cc illustrates the reforming chamber penetration 1152 on the right side of the reformer air plate 1141, it should be understood that the reformer chamber penetrations for the reforming stages alternate the sides along the reformer air plate 1141 with the fuel supply penetrations 1153 to from inlets 1142 to outlets 1143 and can be started on either side of the reformer air plate 1141. Accordingly, the stages immediately before or after stage 1150 will have chamber or reformatting bed penetrations 1152 on the left side of the plate. 1141 and the fuel supply penetrations 1153 on the right side of the reformer air plate 1141. In some embodiments, the stages may be configured differently as appropriate for their intended use and the process and apparatus embodiments described herein are not. should be understood as limited to the alternation of the various penetrations. For example, where the heat exchange includes one or more passages, the configuration may change to accommodate these passages.

In operation, the reformer air stream 126 flows through independent channels 1145 which can supply heat to a portion of the reformer stream 811 by flowing into the independent channels 1105 on the boundary plate 1101 illustrated in figure 11a and a portion of the reformer stream. 811 flowing in the independent channels 1125 shown in Figure 11b through the independent channel walls in each plate. The reformer air stream 126 then proceeds to combustion chamber penetration 1154. Combustion chamber penetrations 1154 combine with the corresponding combustion chamber penetrations 1114, 1134, 1174 and 1194 on the plates in figures 11a-b, def to form the combustion chambers, such as the combustion chambers 851, 852, 853 and 855 illustrated in Figure 8, where the reformer air stream 126 is reheated by catalytic combustion of the fuel from the independent channels 1165 on the plates. reformer fuel 1161. After being reheated, the reformer air stream 126 leaves the combustion chamber and heats the reformer stream 811 at the next reform stage until it leaves the last reform stage and enters the reform air penetrations. where, with reference to figure 8, it leaves the reformer module 150 as flue gas stream 160. Figure 11d illustrates a reformed fuel plate 1161, having reformer fuel inlets 1162, reformer fuel outlets 1163 and flow paths 1164 comprising one or more independent channels 1165. Unlike the serial flow of currents flowing in the plates illustrated in figures 11a-c, a portion reformer fuel stream 124 is supplied individually and independently for each of the stages within the reformer in parallel. Accordingly, each reform stage to which fuel is supplied to the reformer fuel plates 1161 has its own reformer fuel inlets 1162, reformer fuel outlets 1163 and flow path 1164. In addition, the amount of fuel current reformer 124 supplied for each stage may be the same or different from the amount of reformer fuel current supplied for the other stages. As a result, reformer fuel inlets 1162, reformer fuel outlets 1163, and flow paths 1164 for each stage may be configured the same or differently with respect to the other stages. In some embodiments, the amount of reformer fuel stream 124 supplied to each stage after the first stage may be reduced from the previous stage. Additionally, one or more later stages may not receive any part of the reformer fuel stream 124, as the need to reheat the reformer air stream 126 may be reduced or may not exist at some of the later reform stages. One embodiment of a system in which the amount of reformer fuel current supplied to each successive reform stage is reduced is discussed below with respect to Figure 15.

As illustrated in Fig. 11d, flow paths 1164 may be configured to passively control the amount of reformer fuel stream 124 supplied to the reform stages by controlling the size, number and geometry of independent channels 1165 and pressure drops. throughout the reforming system 100. Multiple reforming fuel outlets 1163 may be used for each stage to more evenly supply the reformer fuel stream portion 124 of the combustion penetration 1174 of that stage. Additionally, for some stages, the portion of reformer fuel stream 124 supplied to the stage may be supplied from one or more of the fuel supply penetrations 1173. Accordingly, it should be understood that when referring to a In a single reform stage, a portion of the fuel supplied to this stage may come from a fuel supply penetration 1173 physically associated with a different stage and that the fuel supply penetrations 1173 may be configured to supply fuel to more than one stage. The fuel supply penetrations 1173 combine with the corresponding fuel supply penetrations 1113, 1133, 1153, and 1183 on the plates of figures 11a-c and to form the fuel supply flow access paths or chambers.

As illustrated in the expanded view of the reformer fuel plate 1161 in figure 11 dd, an example of a single stage 1170 reforming of the 14 stages included in the reformer fuel plate 1161 includes a fuel supply penetration 1173, a penetration 1174 combustion chamber and a reformation chamber or bed penetration 1172. Although the expanded view of the reformer fuel plate 1161 illustrates the fuel penetration and supply 1173 on the right side of the reformer fuel plate 1161, understand that the fuel supply penetrations alternate sides along the reformer fuel plate 1161 with the chamber and reformatting bed penetrations 1172. Accordingly, the stages immediately before or after stage 1170 will have the fuel supply penetrations 1173. on the left side of the reformer fuel plate 1161 and the chamber penetrations the a reforming bed 1172 on the right side of the reformer fuel plate 1161. In some embodiments, the stages may be configured differently as appropriate for the intended use and the process and apparatus embodiments described herein should not be construed as being limited to alternation. of the various penetrations.

In operation, a portion of reformer fuel stream 124 flows from fuel supply flow paths or access chambers through fuel inlets 1162 along flow paths 1164 comprising independent channels 1165 through fuel outlets. 1163 and entering combustion chambers 1174 where the fuel portion of the reformer fuel stream 124 is catalytically combusted in the presence of the reformer air stream 126, thereby reheating the reformer air stream 126. The combustion by-products of the reformer part of the fuel from the reformer fuel stream 124 leaves the combustion chamber with the reformer air stream 126.

In some embodiments, Figures 11a-d each include reformer airflow inlet channels 1108, 1128, 1142, and 1168 and reformer airflow outlet channels 1109, 1129, 1143, and 1169. reformer current inlet channels 1108, 1128, 1142 and 1168 may serve to feed reformer air stream 126 into reformer 820 and reformer air inlet penetrations 1115, 1135, 1155 and 1175 and may be supplied through a head that can be welded or connected over the ends of the individual channels through the stack of plates that create the PCR. The inlet penetrations 1115, 1135, 1155 and 1175 may form a chamber which may be an empty chamber that collects the reformer air stream for feed into the flow path 1144 comprising channels 1145. Similarly, the flow channels 1145. reformer current outputs 1109, 1129, 1143 and 1169 may serve to feed the flue gas stream 160 flowing into the individual reformer plates 820 after the final stage of the optional heat and combustion heat exchange for the pipe supplying the flue gas to pre-reformer 800. Channels 1109, 1129, 1143, and 1169 may feed current 160 into a head that can be welded or otherwise connected to the pre-reformer over the ends of the individual channels via the stack of plates that create the PCR. The reformer airflow inlet channels 1108, 1128, 1142, and 1168 and the reformer airflow outlet channels 1109, 1129, 1143, and 1169 may be configured and sized in the same or different manner as channels 1145 and may same or different number of reformer airflow input channels 1108, 1128, 1142, and 1168 and reformer airflow output channels 1109, 1129, 1143, and 1169 compared to channels 1145. Generally, the channels 1108, 1128, 1142, and 1168 airflow inlet ports and the reformer airflow outlet channels 1109, 1129, 1143, and 1169 may independently have the sizes described in Table 1. By the airflow supply configuration Thus, the pressure drop of the current through the reformer can be minimized. Figure 11e illustrates an example of an upper end plate 1180 having fuel supply penetrations 1183. Upper end plate 1180 may be a blank plate or plates without any flow path circuitry and may be isolated to enhance heat transfer and limit heat loss. In some embodiments, a single upper end plate 1180 is used. In other embodiments, multiple upper endplates 1180 may be used to provide sufficient thickness for the fuel supply heads or ports. In some embodiments, a headstock may be supplied and connected, as welded, through the length and width of the top plate and provides the fuel supply for each of the fuel supply penetrations. In some embodiments, this supply may be accomplished by supplying fuel to the head, where the head is a single open space that provides access to each of the fuel supply penetrations, which, by virtue of their configuration, provide the drop in desired pressure to achieve the desired passive control of the fuel supply to the combustion chambers in the reformer. Similarly, as illustrated in Fig. 11f the lower end plate 1190 may be a blank plate or plates without any flow path circuitry and may be insulated to improve heat transfer and limit heat loss. In some embodiments, the lower end plate 1190 may include inputs and outputs for the input and output of one or more of the various streams in addition to chamber or reformatting bed penetrations 1192 and combustion chamber penetrations 1194, which may have gates. connected to them. In some embodiments, multiple lower endplates may be used. In some embodiments, a single lower end plate 1190 is used. In other embodiments, multiple endplates may be used to provide sufficient thickness for the heads or doors. In some embodiments, the end plates provide a wall for the end plate passages facing the end plate, serve as penetration caps and support the connection of PCR relevant currents, such as through the ports or heads. Accordingly, in some embodiments, the endplates must be thick enough to accommodate the pressures in each of the penetrations and to withstand the doors or heads. In some embodiments, the various penetrations in the lower end plates may each be capped with the penetration caps after the plates have been stacked and formed into a reformer. In some embodiments, the penetration caps may comprise any suitable material, including the material from which the plates are formed and may be connected, such as welded or otherwise connected to block, seal or cover the penetrations of the end plates. inferior.

When stacked and diffused or otherwise joined to form a PCR, the various boundary plates 1101, reformer plates 1121, reformer air plates 1141, reformer fuel plates 1161, upper end plates 1180 and lower ends 1190 are preferably aligned such that each of the various reforming chamber or bed penetrations 1112, 1132, 1152, 1172 and 1192 are aligned to form the reforming chambers or reforming beds, such as the reforming chambers or beds. 841, 842, 843, 844 and 845. In addition to the alignment of the chamber or reforming bed penetrations, the stacking of the plates preferably aligns the fuel supply penetrations 1113, 1133, 1153, 1173 and 1183 to form the pathways. or fuel supply stream access chambers and aligns the combustion chamber penetrations 1114, 1134, 1154, 1174 and 1194 to form the combustion chambers, such as the 851, 852, 853, and 855 combustion chambers. Reform chambers or beds and combustion chambers may be loaded with structured or unstructured catalyst and the reforming reaction and combustion reaction may be catalyzed using any suitable catalyst. For such non-penetrating plates and chains through which flow paths and flow channels are accessed, the heads can be fixed, as welded, onto individual channel ends to facilitate current distribution and / or collection. that flows through the relevant channels.

In addition to the alignment of the various penetrations, the stacking of the plates preferably places flow paths 1104 and 1124 in proximity to flow path 1144 to facilitate heat transfer through independent channel walls 1145 into independent channels 1105 and 1125. In some embodiments, such heat transfer occurs in what has been depicted in Figure 8 as heat exchangers, such as heat exchangers 831,832, 833 and 834.

In some embodiments, the plates may be stacked and diffused or otherwise joined in any suitable order to form a PCR version of the reformer 820. In some embodiments, the plates may be stacked and diffused or otherwise joined in the order. at least one upper end plate 1180, a boundary plate 1101, multiple reforming cells, each reforming cell comprising a reformer air plate 1141, reformer fuel plate 1161, a second fuel air plate. reformer 1141 and a reformer plate 1121, and the rest of the stack includes in order a reformer air plate 1141, a reformer fuel plate 1161, a second reformer burner plate 1141, another boundary plate 1101 and a bottom end 1190. Accordingly, the order of the printed circuit reactor boards in a given stack for some 820 reformer modes may have the following pattern for the active boards s (limit plate 1101 = B, reformer flare plate 1141 = A, reformer fuel plate 1161 = F, one reformer plate 1121 = R): BAFARAFA R ... A FAB. A perspective view of a reform cell is illustrated in Figure 12.

In a specific embodiment for reforming 2 natural gas SCMHs, reformer 820 comprises a PCR having 3 upper end plates, followed by a boundary plate 910, followed by 5 reforming cells followed by a 1141 reformer air plate a reformer fuel plate 1161, a second reformer air plate 1141, another limiting plate 1101 and 3 lower end plates. Preferably, reformer 820 comprises a PCR that is constructed from materials suitable to withstand the pressures and temperatures to which reformer 820 is exposed. In some embodiments, the reformer 820 may be constructed from alloy 800H or alloy 617.

The individual plates that create the PCR may independently have the thicknesses described in Table 1. In some embodiments, the plates may each be 1.6 mm. of thickness. Additionally, each of the independent flow channels 1105, 1125, 1145 and 1165 may independently comprise a generally semicircular cross-section and may independently have the dimensions described in Table 1. In some embodiments, independent channels 1105 on boundary plates 1101 may have a depth of 1.10 mm. deep, a width of 1.69 mm. and 1.00 mm. of overhangs. In some embodiments, independent channels 1125 of reformer plates 1121 may have a depth of 1.10 mm, a width of 1.69 mm. and 1.00 mm. of overhangs. In some embodiments, independent channels 1145 in reformer air plates 1141 may have a depth of 1.10 mm, a width of 1.69 mm. and 0.90 mm. of overhangs. In some embodiments, independent channels 1165 on reformer fuel plates 1161 may have a depth of 1.10 mm. , a width of 1.69 mm. and 0.4 mm. of overhangs.

In some embodiments, when the reformer 820 comprises a PCR, the PCR may operate as follows: the reformer current 811 may enter flow paths 1104 and 1124 into boundary plates 1101 and reformer plates 1121, a free-form reformer chamber. catalyst formed by aligning the relevant reformer penetrations into each of the plates creating the PCR including the reformer current input penetrations 1102 and 1122. The reformer current 811 can enter independent channels 1105 and 1125 that create flow paths 1104. and 1124 where it is heated by the reformer air stream 126 that entered the PCR into the reformer air plate 1141 through the reformer air inlets 1141 and independent multi-channel reforming 1145 of flow path 1144. Preferably, the airstream 126 and the reformer current 811 exchanges heat through the walls of its independent channels 1145, 1105 and 1125 while flowing in single pass flow but generally the currents preferably flow in a simultaneous flow direction as illustrated in figure 8. Thus, during actual heat transfer the currents preferably flow in cross-flow relative to each other, but the flow of both currents through the PCR is preferably in a simultaneous flow direction.

After receiving heat from the reformer air stream 126, the reformer stream 811 enters the reforming chamber or bed 841 formed from the alignment of the various chamber or reforming bed penetrations in the PCR plates where the gaseous hydrocarbon in the stream of reformer is partially catalytically reformed. Similarly, after heating the reformer stream 811 the reformer airstream 126 enters combustion chamber 851 where it is reheated by combustion of a fuel portion of the reformer fuel stream 124. The reformer fuel stream portion 124 enters the PCR through one or more of the reformer fuel flow paths or access chambers formed by aligning the relevant fuel supply penetrations on each of the PCR creating plates and enters independent flow path channels 1165. 1164 and through the reformer fuel inlets 1162. The portion of the reformer fuel stream 124 flows through the independent channels 1165 and enters the combustion chamber 851 through the reformer fuel outlets 1163 and the fuel is catalytically combusted in the presence of the reformer airflow 126 to reheat reformer airflow 126 pa the next stage of reform. Thus, the reformer stream 811 and the reformer air stream 126 are subjected to multiple stages of heat exchange, reforming and combustion until the reformer stream 811 leaves the PCR as syngas stream 180 and the reformer 126 let the reformer as the flue gas stream 160.

A top view of the PCR 900 or pre-reformer version 800 and a top view of the PCR 1300 version of the reformer 820 are illustrated in Figures 13a-b. As illustrated, each of the pre-retirement chambers or pre-beds 1310, 1320, 1330 and retirement chambers or beds 1340 are illustrated packaged with reforming catalyst. Similarly, each of the combustion chambers 1350 is illustrated packaged with catalyst. In this version of PCR 1300, the upper plates 1360 also include fuel supply penetrations 1362 which help form fuel supply chambers 1364. Accordingly, in this embodiment of PCR 1300, access to each chamber may be obtained. through the upper plates 1360.

The various PCHE and PCR described herein may comprise plates that include independent flow channels for the various streams. The plates for each PCHE and PCR may, independently for each plate or flow channel, have the dimensions described in Table 1: Table 1: PCHE and PCR Plate Thicknesses and Illustrative Flow Channel Dimensions.

In one embodiment, for reforming 2 natural gas SCMHs using off-gas PSA as fuel, the efficient operation of the reformer module 150 while remaining within material temperatures may have the reforming and combustion temperature profiles that appear similar to those illustrated. Figure 14. While not representing actual data, Figure 14 illustrates a graph 1400 of a desired trend in the temperature profile of the reformer stream 811 and the reformer airstream 126 as they proceed through the 14 stages of reforming. (with last chamber or reforming bed and combustion chamber omitted) with passive control of the fuel supply for each combustion stage so that the amount of fuel supplied decreases from stage to stage. As illustrated, it is believed that the reformer current temperature 811 as it is reformed in each of the reforming chambers or beds 841, 842, 843, etc. of a 14-stage reformer should look similar to that illustrated by line 1401 and the temperature of the reformer air stream 126 should look as it is heated and heat exchanges with the reformer stream 811 as illustrated by line 1410. As illustrated , the average temperature difference between reformer current 811 and reformer air current 126 for each stage should reduce from stage to stage and the temperature of reformer current 811 should rise from stage to stage. Preferably, the rise in temperature of reformer stream 811 should be preceded by an increase in hydrogen partial pressure in reformer stream 811 as a result of the reforming. By raising the temperature with an increase in the hydrogen content in the reformer stream 811, the conditions of metal dust and coke formation should be reduced or avoided. As a result of the rise in stage-to-stage reformer current temperature, the fuel requirements for each successive stage of this mode should be reduced between stages as the heat load required to reheat reformer current 811 and to reheat the fuel. reformer airflow 126 should be reduced from stage to stage. Preferably, as illustrated in Figure 14, the temperature of the reformer stream and the reformer air stream will converge to an asymptote just above 800 ° C.

In some embodiments, the fuel and / or air supply for each of the reform stages may be passively controlled by the pressure control and the pressure drops in the air and fuel currents throughout the reformer system 100. By the passive control of the fuel supply for each of the stages, the amount of heat generated by the combustion of the fuel is controlled thereby controlling the amount of heat supplied to the reformer air stream 126 and finally the reformer current 811 and chambers or associated retirement beds. The inlet fuel pressure on a given line and the pressure drop across the line length determine the volume of fuel that is distributed across that line per unit time. The pressure drop may be adjusted on a fuel line determined, for example, by varying the length of the fuel line, varying the sinuosity of the flow path, that is, the number and seriousness of turns in the fuel line, varying the number of fuel lines and / or variation of fuel line cross-sectional area. Changing one or some of these fuel line characteristics thus adjusts the amount of "resistance" encountered by the fuel flow in a given fuel line en route to a combustion chamber, and can thereby passively control the amount of fuel delivered per unit time. The efficiency of the reforming process is temperature dependent as the methane conversion achieved depends on the maximum temperature achieved. It is also desirable to limit the upper temperature of the metal forming the reformer's physical structure. Therefore, by controlling the amount of fuel fed to each successive combustion chamber by configuring the fuel lines specifically for each reforming stage, metal temperatures can be controlled while providing step-by-step increases in the reforming temperature, thereby increasing , the efficiency of the overall reformer system 100. It is preferable that the control provided by tuning the fuel line settings is passive. In other words, the fuel line configurations themselves provide control without the need for affirmative control mechanisms. For this purpose, it is preferable that fuel lines be configured specifically for the parameters of a particular system. For example, in the PCR version of reformer 820 described with reference to Figs. 11f and 11, each independent channel 1165 that feeds fuel into a combustion chamber may be independently engraved or otherwise formed according to a desired fuel line configuration for each other. this channel to provide a desired resistance. Once the system is manufactured with the fuel lines configured in this way, additional active control mechanisms are preferably unnecessary. By providing such passive control, the reformer system 100 may be simpler and smaller as the use of active flow measurement and control devices is limited or avoided resulting in cost and design benefits and flexible slip ratios.

In some embodiments, to reduce the number of parameters that may be required to achieve adequate resistance for each independent channel 1165, and to facilitate channel fabrication, it is preferable that independent channels 1165 feeding the respective combustion chambers each have one, the same transverse dimension. It is also preferable that all independent channels 1165 be configured for laminar flow so that pressure drop is a direct function of flow for all channels. As such, due to the linear variation in flow with respect to pressure drop, the fuel flow and air flow ratios at each combustion stage can remain relatively constant even during a significant reduction of the reformer system 100. Air distribution and combustion chambers such as combustion chamber 821 is balanced by the design of the plates 1141 and 1161. In addition, the archer pressure arrives through the air lines 1145 and the fuel pressure that arrives through the independent channels 1165 is combined or automatically adjust to match in the combustion chamber to produce the desired amount of combustion for that particular chamber. This pressure balance, in turn, provides the appropriate amount of heat for the reforming reagents as they enter the chamber or associated reforming bed. It is preferable that the pressure drops in each line be set so that the overall fuel pressure is slightly above atmospheric pressure. However, other pressure drops may be established and are within the scope of some modalities. Figure 15 is a diagram of the flow resistances within the air and fuel lines supplying one embodiment of the reformer module. Flow resistances within that network as illustrated in Figure 15 are preferably tuned such that the amount of fuel distributed to each combustion stage through successive reform stage fuel streams 861, 862, 863, etc., decreases through the reformer length despite the fact that the pressure drop that drives the fuel flow increases This reduction through reformer length results in the reduction of reform that occurs at each successive reform stage and the increase in reforming current temperature at each successive reform stage. Figure 15 illustrates the flow resistance in the air and fuel lines associated with the individual components through which the fuel lines flow and is discussed with reference to the currents and components described with respect to figure 1. As illustrated, the supply current 106 is divided into air feed stream 107 and combustion air stream 114. Combustion air stream 114 undergoes flow resistance 1515 associated with valve 115a before proceeding into the heat recovery heat exchanger. syngas 110 heat, where it suffers flow resistance 1511 and leaves the syngas 110 heat recovery heat exchanger as combustion air stream 1514. Similarly, air feed stream 107 and fuel feed stream 105 proceed within the syngas 110 heat recovery heat exchanger where they undergo flow resistances 1512 and 1510, respectively. nte.

After leaving the syngas heat recovery heat exchanger 110, the combustion air stream 1514 and the fuel feed stream 105 are combined to form the fuel and air mixture stream 118. A passively controlled portion of the stream of fuel and air mixture 118 corresponding to preheated air mixture 117 undergoes resistance 1520 as it is divided from fuel and air mixture 118 to be combated in the presence of air supply stream 1508 in air preheater 122. The remaining part of fuel and air mixture 118, preheated fuel mixture 119, is partially catalytically combined in fuel preheater 120, where it undergoes flow resistance 1530 and becomes reformer fuel stream 124. In air preheater 122, air supply 107 is heated by catalytic combustion of the fuel in the preheated air mixture 117, suffers resistance flow 1522 and then suffer flow resistance 1525 as it enters reforming module 150 and becomes reforming air stream 126. Flow resistance 1525 is associated with a non-negligible flow resistance that is physically found after the preheater. 122 at the entrance to the reformer block.

At that point in Figure 15, reformer fuel stream 124 and reformer air stream 126 enter reformer 820. As illustrated, reformer air stream 126 undergoes resistance 1540 in heat exchanger 831 in the first stage of reforming in reformer 820 becoming the airstream of reformer 1550. After leaving heat exchanger 831, the airstream of reformer 1550 is coupled to a passively controlled portion of reformer fuel stream 124, such as reforming stage 861, and the fuel is subsequently burned in the combustion chamber 851 to reheat the reformer air stream 1550. The passively controlled portion of the reformer fuel stream 124 undergoes flow resistance 1560 prior to joining the air stream. 1550 reformer as a result of flow control. Reformer air stream 1550 suffers flow resistance 1541 on heat exchanger 832 in the next reform stage, leaves heat exchanger 832 as reformer air stream 1551 and is combined with a passively controlled portion of the reformer fuel stream. 124, such as reform stage fuel stream 862, which undergoes flow resistance 1561 before combining with reformer air stream 1551. Reformer air stream 1551 is then reheated in combustion chamber 852 and undergoes flow resistance 1542 on heat exchanger 833 in the next reforming stage becoming reformer airstream 1552. After leaving heat exchanger 833, reformer airstream 1552 is combined with a passively controlled portion of the reformer airflow. reformer fuel 124, such as reform stage fuel chain 863, which undergoes flow resistance 1562 before combining with and reformer air 1552, and is reheated by combustion of the fuel in the combustion chamber 853.

Thus, the flow resistance network for air and fuel currents operates through any suitable number of stages represented by 880 in figure 8 and suffers the flow resistances represented by parentheses 1570 and 1571 in figure 15. Just before the last one Reform stage 1553 Reformer airstream is combined with a passively controlled portion of Reformer fuel stream 124, such as Reform stage fuel stream 865, which undergoes flow resistance 1565 before it is combined with current. 1553, and is reheated by the combustion of the fuel in the combustion chamber 855. After being reheated, the reformer air stream 1552 exchanges heat one last time with the reformer stream before leaving the reformer 820 as gas. combustion 160.

In the reformer of Figure 15, there are two routes to any point where fuel and air can mix, and during operation of the equipment, flows down the branches automatically adjust so that the pressures at the mixing points combine. nor. Thus, in some embodiments, the following constraints may be placed on the design pressures and pressure drops of the components in the air and fuel resistance network illustrated in Figure 15 (Px indicates line pressure x, while ΔΡχ indicates pressure drop due to the resistance of the numerical reference x shown in figure 15. P105 (hot) is the pressure in current 105 after experiencing resistance 1510 in the syngas 110 heat recovery heat exchanger and P105 (cold) is the pressure in current 105 before entering the syngas heat recovery heat exchanger 110): PpREVIOUS STAGE ”ΔΡηεΑΤ exchanger previous stage In a mode for reforming 2 SCMH of natural gas using PSA off-gas as fuel, a suitable solution for pressure drops meeting the above restrictions on a PCR reformer comprising 14 reforming stages is illustrated in Table 2 below using the references in a 1 and 8 used to identify the components or currents within which pressure drop occurs where appropriate. Note that for the reform stages represented by parentheses 836 and 826 in Figure 8, the relevant combustion / heat exchanger stages or reform stage fuel streams are identified by numerical references 836 (x) and 826 (x) , respectively, where x is a letter of the alphabet starting with "a" and proceeding through the alphabet for each successive reform stage. Thus, for the first reform stage represented by parentheses 836 and 826, the reformer airflow is represented by 836 (a) and the reform stage fuel supply is represented by 826 (a), and so on.

Table 2: Examples of Adequate Pressure Drops in Fuel and Air Currents in a Reform System In a mode for reforming 2 natural gas SCMH using PSA off-gas as fuel comprising 14 reform stages and starting with the fuel on line 117 sent to combustion chamber 122 to reformer air stream 126 and proceeding through each of the successive reform stage fuel streams 861, 862, 863, the proportion of fuel stream 118 sent inwardly. of each row can be as indicated in Table 3 below. Note that for the stages in figure 8, represented by parentheses 826, the numerical references used are 826 (x) where x is a letter of the alphabet starting with "a" and descending the alphabet for each successive reform stage.

Table 3: Example of Fuel Distribution in a 14-Stage Reformer Preferably, a high degree of accuracy is not required on the fuel distribution rate in some reformer modalities, but in some embodiments, the fuel addition rate at each stage. generally decreases as the reformer temperature rises to keep the reforming temperatures low but close to the material design temperature for the equipment. In some embodiments, the drawing temperature may be in the order of 802 ° C or higher. Higher temperatures may favor methane conversion within the reformer, but may also create harsher operating conditions for building materials. Since the heat transfer coefficients of the gases on the reforming side are considerably higher than those on the combustion side, the overall temperature of the building materials tries to stay close to the reforming gas temperature and thus in some In both embodiments, flue gas temperatures may exceed the material design temperature. In order to achieve fuel and air mixtures throughout the reformer that will achieve the desired temperature profiles, the combustion and heat exchange components are preferably designed to match their primary functions while ensuring that the pressure drops associated with each correspond to those necessary for the safe mixing of fuel and air. Preferably, the pressure drops to the air and fuel currents through the reformer 820 are low, such as less than 50 kPa, less than 30 kPa, less than 25 kPa, less than 20 kPa, less than 17.73 kPa, less than 50 kPa. at 15 kPa, less than 12.66 kPa or less than 10 kPa or about 10 kPa or less in total to avoid inefficiencies associated with high fan power consumption. Additionally, the incoming fuel supply stream 104 may also be sensitive to pressure drop. For example, where the fuel supply stream 104 is off-gas from a PSA system, a high fuel pressure drop requiring high fuel inlet pressure may reduce the efficiency of the PSA system.

In some embodiments, it is desirable that the selected flow distribution and corresponding plate configurations be suitable for a wide range of reduction conditions. This can be accomplished by designing relevant reformer plates, heat exchangers and combustion chambers, and the relevant flow paths for the fuel and air currents such that the pressure drop is essentially proportional to the flow rates (ie. the flow is essentially laminar (in straight passages the flow is essentially laminar when the Reynolds Number is less than 2000). By maintaining laminar flow, safe fuel distribution can be maintained at very low reduction conditions, as shown in Table 4 below 10% of the operating capacity of a 2 SCMH natural gas overhaul using PSA off-gas. as a fuel comprising 14 reform stages when compared to the design capability. The data in Table 4 assumes that air flow varies proportionally to capacity, but that no additional fuel and air system controls are required.

Table 4: Fuel Flow Comparison between Drawing Capacity and 10% Capacity Reduction.

In the PCR modalities of reformer 820, the reformer design may be a four-way balance between the air pressure drop on the reformer 1141 air plate, the fuel pressure drop on the reformer 1161 fuel plate, the required heat by the endothermic reforming reaction in the reforming chambers or beds and limiting the maximum temperature produced in the combustion chambers to temperatures suitable for the building materials. To simplify the surrounding system requirements, the reformer fuel plate 1161 and the reformer air plate 1141 are preferably configured to provide a reduced or minimal pressure drop. As mentioned above, air and fuel are preferably distributed to combustion chambers slightly above atmospheric pressure, preferably eliminating the need for fuel compression to perform the combination of the four variables and thereby avoiding the associated additional cost, complexity and lack of fuel. reliability.

In some embodiments, therefore, the design of the independent channels 1165 can control the amount of fuel being distributed into each respective combustion chamber with only one external fuel supply variable needing to be controlled, and that is the fuel pressure as it is being supplied to the fuel line that feeds each of the fuel supply flow pathways or chambers formed from the fuel supply penetrations. The fuel pressure is preferably controlled to maintain the reformer airflow temperature at a level to limit the maximum overall reformer temperature while supplying the heat required by the endothermic reformation reaction. The need for fuel compression is preferably eliminated by designating all independent channels 1165 for minimum pressure drop. The fuel delivery system described above provides several benefits over the prior art. For example, the metered addition of fuel to each stage preferably limits the heat that can be added to each stage, thus facilitating the elimination of the combustion equilibrium, heat transfer and reforming reaction that must be achieved radially or axially. in the tubular reformers. In addition, interstage heat exchangers feature micro-structure construction (PCHE), which supports higher heat transfer coefficients, minimizes equipment size and high alloy utilization thus reducing costs, and can be configured with a large face area and short flow path for low pressure drops. In addition heat exchangers are readily characterized by engineering analysis without the need for expensive full-scale product testing to validate performance.

In a preferred embodiment, a cross flow arrangement is used for the heat exchange aspect of the reformer 820 and a simultaneous flow arrangement may be used for the reforming aspect of the reformer 820. The use of a cross flow arrangement in the aspect Heat exchange may allow a greater proportion of the PCR plate area to be devoted to heat exchange tasks than can be achieved with simultaneous flow or reverse flow arrangements, including those employing multiple passages. For this purpose, the reformer 820 cross-flow heat exchanger component may be coupled with the simultaneous flow reforming chamber or bed component to produce satisfactory temperature profiles for the reformer current as it travels through a chamber or retirement bed to another within the series of stages of reform.

A potential problem with this cross flow configuration concerns the possible temperature variation at the heat exchanger outlet temperature of each stage as a significant variation in the heat exchanger outlet temperature would result in a wide variation in the reaction characteristics in the chamber. associated downstream reformer and catalyst. Simulation studies of the eighth heat exchange stage of a 2 SCMH natural gas reforming mode using PSA off-gas as a fuel comprising 14 reforming stages, without considering the wall heat conduction and assuming the fluid enters the Heat exchanger at a uniform temperature of about 730 ° C showed that fluid exited the heat exchanger at a temperature range of about 765 to 825 ° C as illustrated in Figure 17. Such a wide range of exchanger outlet temperature heat can result in a wide range of reforming reaction characteristics. However, when the wall heat conduction effect was included, the heat exchanger output temperature range for the eighth heat exchange stage was significantly smaller, as illustrated in Figure 18, for example, of the order of about 15 ° C, or about 780 ° C to about 795 ° C. In both figures 17 and 18, with the temperature along the z axis, the x and y axes represent the dimensions of the cross flow heat exchanger with the reformer air stream flowing along the shorter geometry axis from the upper right side to the lower left side and the reformer stream flowing along the longest geometry axis from the lower right to the upper left side in cross flow with respect to the reformer airflow. The narrow outlet temperature range may result from the fact that the heat exchanger walls in some embodiments are preferably thicker than those of typical fin heat exchangers. As such, it is believed that there is a lengthwise conduction along the wall which serves to reduce the range of outlet temperatures. Therefore, it is preferable to use a simple cross-flow contact in the heat exchangers that allows for greater use of the heat exchange plates.

In other embodiments of some PCRs, the reformer air stream and the reformer stream may generally be configured in an opposite flow arrangement, but may employ a number of cross flow passages to achieve the opposite flow effect. In this situation, to achieve the opposite flow effect, an amount of plaque area may be inactive for heat transfer. For this purpose, the reforming gas may be carried from each reforming bed to the far edge of the interstage heat exchanger before entering the heat exchanger, and then is carried from the near end of the heat exchanger to the successive reforming bed. . However, areas consumed in bringing the reformer current between the distant and near ends of the heat exchanger to and from the reforming beds may be inefficient for heat exchange, and may thus compromise the efficiency of material use. of reformer plate. In addition, multiple passage of the reformer current at each stage may limit the width of each plate element if the pressure drop does not become too excessive, and thus compounding the loss in efficiency of the use of the reformer material. as the proportion of the plate area that is inefficient for heat exchange is kept high. Accordingly, although workable, such a configuration is not the preferred configuration. The use of cross-flow heat exchange preferably avoids the need to carry the reformer current from one end of the heat exchanger to the other end to achieve the opposite flow heat exchange characteristics. As such, the use of cross flow generally reduces the amount of plate area required for heat exchange. Additionally, by reducing the number of passages, the pressure drop through the heat exchangers is reduced which in turn reduces the number of channels required. The cross flow arrangement also preferably allows the use of wider plate elements without generating undue pressure drop on the reforming side, such as the plates illustrated in Figure 16 described below.

The use of a general concurrent flow configuration for the process reforming aspect is believed to reduce the reformer's temperature control requirements as reforming and reformer air currents flow in the same direction across the length. of the simultaneous flow configuration, their temperatures tend to converge. Thus, control of the output temperature of one of the currents results in the output temperature of both currents being controlled. Figure 19 illustrates the composite hot and cold enthalpy curves for a reformer system embodiment. Curve 1910 represents the composite heat curve for the hot process currents, that is, those currents that are cooled in the heat exchangers, and curve 1920 is the composite curve for the cold process currents. The closest vertical approach to the curves is approximately 34 ° C and may be referred to as temperature "narrowing". Since heat cannot flow from cold to hot currents (2nd Law of Thermodynamics), the highest possible heat recovery efficiency occurs for zero narrowing. Thus, the smaller the narrowing, the greater the overall heat recovery efficiency. In this respect, a narrowing of 34 ° C is quite small, especially considering that one of the currents involved in heat transfer is low pressure air or flue gas having low heat transfer characteristics. Note that in addition to the heat recovery efficiency the vapor ratio and methane conversion also support the overall process efficiency as reflected in the formula described herein. Ideally, to avoid loss of efficiency, heat should not be transferred through the nip (from above the nip to below the nip) in any heat exchanger. Some process or apparatus embodiments limit this occurrence by the process schemes, although in some embodiments such transfer does not occur to a lesser extent in the heat exchanger 164.

It should be noted that the fourteen stage modality of reformer 820 described above with respect to figures 11 and 12 is only an example and should not limit the modalities of the reformer. Nor is it necessary that the number of reforming and combustion stages be equal. In fact, different plate sizes, configurations and / or the use of any suitable number of reforming and combustion plates and chambers so that the reformer 820 can be scaled up or down to meet process requirements are specifically contemplated. Indeed, the printed circuit reformer design of some embodiments of the reformer 820 allows the reformer 820 to be readily staggered up and down at no significant cost associated with the up or down staggering of a typical tubular reformer. For example, where greater reformatting capacity is required, the size of reformer 820 can be increased by adding more plates or cells to the stack.

As another example for increasing capacity, the plates may be enlarged as shown in Figure 16 by expanding the plates in a lateral direction rather than increasing the number of plates in the stack. As illustrated in Fig. 16, boundary plates 1601, reformer plates 1621, reforming air plates 1641 and reformer fuel plates 1661 can be configured essentially as a sideways mirror image combination of two of the corresponding plates discussed. previously with respect to figures 11a-d. As illustrated, each plate has two independent flow paths 1604 and 1608, 1624 and 1628, 1644 and 1648 and 1664 and 1668, respectively, which share a central set of chamber or retread bed penetrations and fuel supply chamber penetrations. 1615 and 1616, 1635 and 1636, 1655 and 1656 and 1675 and 1676, respectively. Since the chambers formed from the central set of penetrations are shared, the chambers and the penetrations forming them are correspondingly larger than the chambers formed from the independent independent reform bed or chamber penetrations and the chamber penetrations. fuel supply 1612 and 1613, 1632 and 1633, 1652 and 1653 and 1672 and 1673, which may generally correspond to the fuel supply chamber and reforming chamber or bed penetrations discussed above with respect to figures 11a-11d. Each of the plates also includes two sets of combustion chamber penetrations 1614 and 1618, 1634 and 1638, 1654 and 1658 and 1674 and 1678 respectively which may generally correspond to the combustion chamber penetrations discussed above with respect to Figures 11a-11. d.

It should also be understood that the PCR plates corresponding to the reformer 820 may also be lengthened or shortened to include more or less stages of reforming. In addition, it should be understood that similar modifications as described above may be made to the preformer and any of the heat exchangers described herein having the PCHE construction.

In some embodiments, the temperatures and pressures of some of the various currents are interrelated and may have the properties as shown in tables 5-8 below with reference to the configuration for the reforming system illustrated in figure 1 and figure 8 with the current. combustion air 114 combining with the fuel feed stream 105 within the syngas heat recovery heat exchanger 110. In some cases the values are given relative to other values in the Tables, such as, for example, "with Reform Pressure "," Reform Temperature "," Replace Atmospheric Pressure ", or" Replace Saturated Temperature ", in which case the values shown may be above or below (" + xxx "/" - yyy ") or a multiple (" times ") of the identified property, illustrating the interlinking of the properties. Additionally, in some cases, the displayed values may refer to a specific physical parameter such as "above dew point" or "above freezing point", in which case the identified current must meet the requirements based on the parameter. identified physical current. "Reform pressure" or "Reform temperature" in the tables refers to the properties associated with the syngas 180 current. It should be understood that the values shown are by way of example only and that different configurations of the reforming system may be may have different conditions in one or more of the relevant currents.

Table 5: Temperature and Pressure Properties of Some Process Currents of a Modality According to Figure 1 Table 6: Temperature and Pressure Properties of Some Process Currents of a Modality According to Figure 1 Table 7: Temperature Properties and Pressure of Some Process Currents of a Mode According to Figure 1 Table 8: Temperature and Pressure Properties of Some Process Currents of a Mode According to Figure 1.

Figures 20 and 21 illustrate front and rear perspective views of a partial embodiment of one embodiment of a reformer system 700. Figures have been simplified by removing the tubing parts. The embodiment illustrated corresponds to a system having the scheme of figure 7. As such, only the air supply stream 107, the combustion air stream 114, the fuel stream 104, the gaseous hydrocarbon stream 102 enter the heat exchanger. syngas 110 heat recovery heat and water stream 108 enters heat exchanger 109, which is part of syngas 110 heat recovery heat exchanger, to exchange heat with syngas 190 current leaving the change reactor 186. Among the streams or piping not shown is the division of the fuel and air mixture leaving the syngas heat recovery heat exchanger 110 to feed the fuel and air into the leaving air stream. syngas 110 heat recovery heat exchanger, before streams enter preheaters 120 and 122 as this occurs within head 2010 which supplies preheater 120 with relative to head 2015 for preheater 122. After being preheated on preheater 120, the fuel leaves the preheater as the reformer fuel stream and enters a fuel supply head 202 that covers the length of the reformer 820 and supplies the supply. for each of the individual fuel supply flow pathways or access chambers in the reformer stack. In this way, fuel can be supplied to each of the reformer stages in parallel and the supply can be passively controlled by the individual fuel supply chain configurations that connect to each combustion chamber in the reformer. Since this embodiment corresponds to an embodiment according to Fig. 7, the water stream 108 receives heat directly from the flue gas stream 160 as it exits pre-reformer 800 without any preheating of the flue gas stream. After leaving heat exchanger 164, water stream 108 proceeds to cool heat exchanger 165, where it receives heat from a portion of syngas stream 180 after it is split shortly after leaving reformer 820. As illustrated in the figures 20 and 21, pre-reformer 800 and reformer 820 each comprise PCRs that are stacked and diffusion joined plates as described with respect to FIG. 9 and FIG. 11, respectively, and then placed on their sides.

Further in FIGS. 20 and 21, the gaseous hydrocarbon vapor head 2102 which feeds the gaseous hydrocarbon vapor stream 174 to the gaseous hydrocarbon vapor channels in the reformer gaseous steam plates 800 and reformer chain 2104 that collects reformer current 811 as it leaves pre-reformer 800 through the reformer current channels. From head 2104, reformer chain 811 connects to reformer chain head 2110 which feeds the reformer current input channels of the boundary plates and reformer plates that are included with reformer 820. Figures 20 and 21 also include the syngas 2106 chain head that collects the reformed currents leaving the reformer boundary plates and reformer plates 820 through the reformer current output channels to form the syngas current 180. In Figure 21, the The combustion chamber and the reforming chamber created by stacking the plates are illustrated without cap with the penetration caps 2108, which can be connected, such as by welding or otherwise connected over the combustion chamber and the reforming chamber penetrations into the plate. reformer end cap 820.

All publications and patent applications mentioned in that specification are incorporated herein by reference as if each individual publication or patent application had been specifically and individually indicated to be incorporated by reference.

While preferred embodiments of the present invention have been illustrated and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is intended that the following claims define the scope of the invention and that the methods and structures within the scope of these claims and their equivalences are covered by them.

Claims (27)

A hydrocarbon gas vapor reforming process, comprising: the partial combustion of fuel in a first fuel and air mixture stream to heat the fuel and air mixture stream for use during the reforming of a gas vapor stream. hydrocarbon; combustion of a second fuel and air mixture stream to heat an air stream for use during reforming the hydrocarbon vapor gas stream; and reforming the hydrocarbon vapor gas stream to form a syngas stream and a flue gas stream. A process according to claim 1 further comprising: reducing metal dust and / or coke during the reforming step by heating and preforming the hydrocarbon vapor gas stream at multiple pre-reforming stages prior to reform of the hydrocarbon vapor gas stream. A process according to claim 2, wherein heating comprises recovering heat from the flue gas stream into a gaseous hydrocarbon vapor stream in a heat exchanger. The process of claim 1, wherein said reforming comprises at least three stages of: i) heating the hydrocarbon vapor gas stream by recovering heat from the heated air stream to form a heated reforming stream and a cooled air stream; (ii) reform of at least part of the heated reform stream; and iii) combustion of a portion of the partially blown air-fuel mixture stream in the presence of the cooled air stream to reheat the cooled air stream. A process according to claim 4 wherein the amount of fuel and air mixture supplied to the combustion step of each of the at least three stages is passively controlled. A process according to claim 5 wherein said passive control is performed by balancing pressure drops in the fuel and air lines throughout the hydrocarbon gas vapor reforming process. A process according to claim 1, wherein said process has a hydrocarbon conversion of more than 50%. A process according to claim 1, wherein said process has an energy efficiency of more than 50%. A process according to claim 1, wherein the conditions of metal dust and coke are avoided within all heat exchangers, pre-reform stages and reform stages within the process. A gaseous hydrocarbon vapor reforming process comprising: (a) preheating one or more air streams to form one or more preheated air streams; b) combining at least one air stream with a portion of the at least one fuel stream to form a fuel and air mixture having a temperature below metal dust conditions; c) partial combustion of the fuel in a portion of the fuel and air mixture to form a heated fuel stream having a temperature above the metal dust conditions for use in the reformer stages; d) combustion of a portion of the fuel and air mixture in the presence of at least one of the preheated air streams to form a heated air stream having a temperature above the metal dust conditions for use in the reformer stages; e) heating one or more streams of water to form steam; f) mixing the vapor with one or more hydrocarbon gas streams to form a hydrocarbon vapor gas stream; g) heating and partially reforming the hydrocarbon vapor gaseous stream at one or more pre-reforming stages to form a reformer stream, wherein through all one or more pre-reforming stages the hydrocarbon vapor gaseous stream has a combination of temperature and composition that avoids metal dust and coke conditions; h) reforming the reformer stream into one or more stages of the reformer to form a syngas stream and a flue gas stream, where at one or more stages of reforming the reformer stream has a combination of temperature and composition which avoids metal dust and coke conditions; (i) recovering heat from the flue gas stream to provide heat to the preform stages in step g) and to provide preheat to the water stream; and j) heat recovery from the syngas stream to preheat the air stream from step a) and to provide heat to form the steam in step e). The process of claim 10, wherein each of said pre-reforming stages comprises: i) recovering heat from said flue gas stream to heat said hydrocarbon vapor gas stream; and ii) partial reforming of the heated hydrocarbon vapor gas stream. A process according to claim 10, wherein said reforming and reheating the reformer stream into one or more reformer stages to form a syngas stream and a flue gas stream comprise multiple stages of: i) heating the reformer stream by recovering heat from the heated air stream in a heat exchanger to form a heated reformer stream and a cooled air stream; (ii) renovation of at least part of the heated reformer stream; and iii) combustion of a portion of the heated fuel stream in the presence of the cooled air stream to form the heated air stream for the next stage. A process according to claim 11 further comprising cooling at least a portion of the syngas stream in a cooled heat exchanger. 14. A gaseous hydrocarbon vapor reforming apparatus, comprising: (a) a fuel preheater causing partial combustion of the fuel in a first fuel and air mixture to form a heated fuel stream, the heated fuel stream being combined into a reformer module; b) a preheater causing a part of a second fuel and air stream to be combusted in the presence of an air stream to form a heated air stream, the heated air stream supplying heat to the reformer module; c) a reformer module for forming a syngas stream from a reformer stream. Apparatus according to claim 14, wherein said reformer module comprises one or more pre-reformer stages and one or more reformer stages. Apparatus according to claim 15, wherein each of said pre-reformer stages comprises a heat exchanger and a catalyst chamber. Apparatus according to claim 16, wherein said pre-reformer stages are configured to recover heat through the heat exchanger from a flue gas stream leaving the reformer module. Apparatus according to claim 15, wherein said reformer stages comprise: i) a heat exchanger that heats the reformer stream by recovering heat from the heated air stream to form a cooled air stream. ; ii) a retirement bed reforming the heated reformer current; and iii) a combustion chamber that causes a portion of the heated fuel stream to be combusted to reheat the cooled air stream. Apparatus according to claim 18, wherein said apparatus includes a fuel distribution control network configured for passive control of the amount of heated fuel current supplied to each combustion chamber in the reformer stages. Apparatus according to claim 14, wherein said apparatus further comprises at least one heat exchanger which recovers heat from said syngas stream after leaving the reformer module. Apparatus according to claim 20, wherein said at least one heat exchanger comprises at least one cooled heat exchanger that recovers heat from a portion of said syngas stream. Apparatus according to claim 20, wherein said at least one heat exchanger comprises a multistage heat exchanger. Apparatus according to claim 14, wherein said apparatus is configured to prevent or reduce the conditions of metal dust and coke within all heat exchangers, pre-reform stages and reform stages. Apparatus according to claim 14, further comprising a water and gas change reactor that increases the hydrogen concentration in the syngas stream after the syngas stream leaves the reformer module. 25. A gaseous hydrocarbon vapor reforming apparatus comprising: (a) a syngas heat recovery heat exchanger that recovers heat from a syngas stream to heat at least one air stream; b) an air flow divider that divides the air stream into a first air stream and a second air stream, the first air stream connecting to a fuel stream to form a fuel and air mixture; c) a fuel flow divider that divides the fuel and air mixture into a first fuel and air stream and a second fuel and air stream, the first fuel and air stream connecting to a fuel preheater and the second stream fuel and air by connecting to an air preheater; d) a fuel preheater causing partial combustion of the fuel in the first fuel stream and air to form a heated fuel stream for use in the reformer; e) an air preheater causing combustion of the second fuel and air stream in the presence of the second air stream to form a heated air stream for use in the reformer; f) a pre-reformer partially reforming a heated hydrocarbon gas stream in the presence of steam to form a reformer stream; g) a reformer reforming the reformer stream to form a syngas stream; h) a cooled exchanger that recovers heat from the syngas stream to form steam from a water stream to the preformer. Apparatus according to claim 25, wherein said pre-reformer comprises a printed circuit reactor. Apparatus according to claim 25, wherein said reformer comprises a printed circuit reactor.